Rotary powered surgical instrument with manually actuatable bailout system

ABSTRACT

A motor-driven surgical instrument is disclosed. The surgical instrument comprises a motor that is supported in a housing and includes at least one rotary drive system that is configured for selective operable engagement and disengagement with the motor assembly. A bailout drive train is supported by the housing assembly and is configured for selective operable engagement and disengagement with the at least one rotary drive system. A bailout handle assembly is selectively movable between a stored position within the housing assembly and an actuation position such that, when the bailout handle assembly is in the stored position, the at least one rotary drive system is retained in operable engagement with the motor assembly and when the bailout handle assembly is in the actuation position, the bailout drive train is in operable engagement with the at least one rotary drive system.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of a surgical instrument including aninterchangeable surgical tool assembly in accordance with at least oneembodiment;

FIG. 2 is another perspective view of a handle assembly of the surgicalinstrument of FIG. 1, with a portion of the handle housing omitted toexpose components housed therein;

FIG. 3 is an exploded assembly view of portions of the handle assemblyof the surgical instrument of FIGS. 1 and 2;

FIG. 4 is a cross-sectional perspective view of the handle assembly ofFIGS. 2 and 3;

FIG. 5 is a partial cross-sectional side view of the handle assembly ofFIGS. 2-4 with a grip portion of the handle assembly shown in solidlines in one position relative to a primary housing portion and inphantom lines in another position relative to the primary housingportion of the handle assembly;

FIG. 6 is an end cross-sectional view of the handle assembly of FIGS.2-5 taken along line 6-6 in FIG. 5;

FIG. 7 is another end cross-sectional view of the handle assembly ofFIGS. 2-6 taken along line 7-7 in FIG. 5;

FIG. 8 is another end cross-sectional view of the handle assembly ofFIGS. 2-7 showing a shifter gear in meshing engagement with a drive gearon a rotary drive socket;

FIG. 9 is another end cross-sectional view of the handle assembly ofFIGS. 2-8 showing the position of a shifter solenoid when the shiftergear is in meshing engagement with the drive gear on the rotary drivesocket;

FIG. 10 is another perspective view of the handle assembly of FIGS. 2-9with certain portions thereof shown in cross-section and with an accesspanel portion thereof shown in phantom;

FIG. 11 is a top view of the handle assembly of FIGS. 2-11 with abailout system shown in an actuatable position;

FIG. 12 is a perspective view of a bailout handle of the bailout systemdepicted in FIGS. 2-11;

FIG. 13 is an exploded assembly view of portions of the bailout handleof FIG. 12 with portions thereof shown in cross-section;

FIG. 14 is a cross-sectional elevation view of the handle assembly ofFIG. 11;

FIG. 15 is a perspective view of the handle assembly of FIGS. 2-11 and atool attachment module portion of the interchangeable surgical toolassembly of FIG. 1;

FIG. 16 is a partial cross-sectional perspective view of the toolattachment module portion of FIG. 15;

FIG. 17 is an exploded assembly view of portions of the interchangeablesurgical tool assembly of FIG. 16;

FIG. 18 is an exploded assembly view of the tool attachment module ofFIG. 16;

FIG. 19 is a perspective view of one form of a shaft coupler releaseassembly;

FIG. 20 is a side cross-sectional view of the tool attachment module ofFIGS. 16 and 18 being aligned for installation on a tool mountingportion of the handle assembly of FIG. 1;

FIG. 21 is another side cross-sectional view of the tool attachmentmodule of FIG. 20 being initially inserted into tool mounting portion ofthe handle assembly of FIG. 1;

FIG. 22 is another side cross-sectional view of the tool attachmentmodule of FIGS. 20 and 21 attached to the tool mounting portion of thehandle assembly of FIG. 1;

FIG. 23 is a perspective view of the interchangeable surgical toolassembly of FIG. 1;

FIG. 24 is a cross-sectional perspective view the interchangeablesurgical tool assembly of FIG. 23;

FIG. 25 is a perspective view of a surgical end effector portion of theinterchangeable surgical tool assembly of FIG. 23;

FIG. 26 is a cross-sectional perspective view of the surgical endeffector of FIG. 25;

FIG. 27 is an exploded assembly view of the surgical end effector ofFIG. 25;

FIG. 28 is a partial rear cross-sectional view of the surgical endeffector of FIG. 25;

FIG. 29 is a cross-sectional perspective view of a firing member orcutting member in accordance with at least one embodiment;

FIG. 30 is a cross-sectional elevational view of an articulation jointin accordance with at least one embodiment;

FIG. 31 is a cross-sectional view of the surgical end effector of FIG.25 with the firing member of FIG. 29 in a firing position;

FIG. 32 is another cross-sectional view of the surgical end effector ofFIG. 25 with the firing member FIG. 29 in an ending position;

FIG. 33 is another cross-sectional view of a portion of the surgical endeffector of FIG. 25 with an anvil assembly in an open position;

FIG. 34 is another cross-sectional view of a portion of the surgical endeffector of FIG. 25 with the firing member of FIG. 29 in a pre-firingposition;

FIG. 35 is another cross-sectional view of a portion of the surgical endeffector of FIG. 34 wherein the firing member has been returned to astarting position to thereby urge the internally threaded closure nutinto threaded engagement with the closure thread segment on the distalpower shaft;

FIG. 36 is a perspective view of a bearing spring in accordance with atleast one embodiment;

FIG. 37 is an exploded assembly view of the articulation joint of FIG.30;

FIG. 38 is a top view of the articulation joint of FIG. 30 with thesurgical end effector of FIG. 25 in an unarticulated orientation;

FIG. 39 is another top view of the articulation joint of FIG. 30 withthe surgical end effector in a maximum articulated orientation;

FIG. 40 is a perspective view of a portion of the elongate shaftassembly of FIG. 23 showing the articulation joint of FIG. 30 andportions of a surgical end effector rotary locking system embodiment;

FIG. 40A is a partial exploded perspective view of an articulation jointand end effector illustrating one arrangement for facilitating thesupply of electrical signals to the end effector around the articulationjoint in accordance with at least one embodiment;

FIG. 40B is a side elevational view of the articulation joint and endeffector of FIG. 40A with some components thereof shown incross-section;

FIG. 41 is a partial cross-sectional perspective view of the surgicalend effector rotary locking system of FIG. 40 in an unlockedorientation;

FIG. 42 is another partial cross-sectional perspective view of thesurgical end effector rotary locking system of FIGS. 40 and 41 in anunlocked orientation;

FIG. 43 is a top view of the surgical end effector rotary locking systemof FIGS. 40-42 in a locked orientation; and

FIG. 44 is a top view of the surgical end effector rotary locking systemof FIGS. 40-43 in an unlocked orientation.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/089,325, entitled METHOD FOR        OPERATING A SURGICAL STAPLING SYSTEM, now U.S. Patent        Application Publication No. 2017/0281171;    -   U.S. patent application Ser. No. 15/089,321, entitled MODULAR        SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY, now U.S. Patent        Application Publication No. 2017/0281163;    -   U.S. patent application Ser. No. 15/089,326, entitled SURGICAL        STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE        DISPLAY FIELD, now U.S. Patent Application Publication No.;        2017/0281172;    -   U.S. patent application Ser. No. 15/089,263, entitled SURGICAL        INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION, now        U.S. Patent Application Publication No. 2017/0281165;    -   U.S. patent application Ser. No. 15/089,277, entitled SURGICAL        CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE        MEMBER, now U.S. Patent Application No. 2017/0281166;    -   U.S. patent application Ser. No. 15/089,283, entitled CLOSURE        SYSTEM ARRANGEMENTS FOR SURGICAL CUTTING AND STAPLING DEVICES        WITH SEPARATE AND DISTINCT FIRING SHAFTS, now U.S. Patent        Application Publication No. 2017/0281167;    -   U.S. patent application Ser. No. 15/089,296, entitled        INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END        EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS, now        U.S. Patent Application Publication No. 2017/0281168;    -   U.S. patent application Ser. No. 15/089,258, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION, now U.S.        Patent Application Publication No. 2017/0281178;    -   U.S. patent application Ser. No. 15/089,278, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF        TISSUE, now U.S. Patent Application Publication No.        2017/0281162;    -   U.S. patent application Ser. No. 15/089,284, entitled SURGICAL        STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT, now U.S. Patent        application Publication No. 2017/0281186;    -   U.S. patent application Ser. No. 15/089,295, entitled SURGICAL        STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT, now        U.S. Patent Application Publication No. 2017/0281187;    -   U.S. patent application Ser. No. 15/089,300, entitled SURGICAL        STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT, now U.S.        Patent Application Publication No. 2017/0281179;    -   U.S. patent application Ser. No. 15/089,196, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT, now U.S.        Patent Application Publication No. 2017/0281183;    -   U.S. patent application Ser. No. 15/089,203, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT, now U.S.        Patent Application Publication No. 2017/0281184;    -   U.S. patent application Ser. No. 15/089,210, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT, now U.S.        Patent Application Publication No. 2017/0281185;    -   U.S. patent application Ser. No. 15/089,324, entitled SURGICAL        INSTRUMENT COMPRISING A SHIFTING MECHANISM, now U.S. Patent        Application Publication No. 2017/0281170;    -   U.S. patent application Ser. No. 15/089,335, entitled SURGICAL        STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS, now U.S.        Patent Application Publication No. 2017/0281155;    -   U.S. patent application Ser. No. 15/089,339, entitled SURGICAL        STAPLING INSTRUMENT, now U.S. Patent Application Publication No        2017/0281173;    -   U.S. patent application Ser. No. 15/089,253, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES        HAVING DIFFERENT HEIGHTS, now U.S. Patent Application        Publication No. 2017/0281177;    -   U.S. patent application Ser. No. 15/089,304, entitled SURGICAL        STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET, now U.S.        Patent Application Publication No.; 2017/0281188;    -   U.S. patent application Ser. No. 15/089,331, entitled ANVIL        MODIFICATION MEMBERS FOR SURGICAL STAPLERS, now U.S. Patent        Application Publication No. 2017/0281180;    -   U.S. patent application Ser. No. 15/089,336, entitled STAPLE        CARTRIDGES WITH ATRAUMATIC FEATURES, now U.S. Patent Application        Publication No. 2017/0281164;    -   U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR        STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT, now U.S.        Patent Application Publication No. 2017/0281189;    -   U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR        STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM, now U.S. Patent        Application Publication No. 2017/0281169; and    -   U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR        STAPLING SYSTEM COMPRISING LOAD CONTROL, now U.S. Patent        Application Publication No. 2017/0281174.

The Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS        FOR COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 14/984,552, entitled SURGICAL        INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

The Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/019,220, entitled SURGICAL        INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END        EFFECTOR;    -   U.S. patent application Ser. No. 15/019,228, entitled SURGICAL        INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,196, entitled SURGICAL        INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY        CONSTRAINT;    -   U.S. patent application Ser. No. 15/019,206, entitled SURGICAL        INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE        RELATIVE TO AN ELONGATE SHAFT ASSEMBLY;    -   U.S. patent application Ser. No. 15/019,215, entitled SURGICAL        INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,227, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK        ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,235, entitled SURGICAL        INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN        ARTICULATION SYSTEMS;    -   U.S. patent application Ser. No. 15/019,230, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM        ARRANGEMENTS; and    -   U.S. patent application Ser. No. 15/019,245, entitled SURGICAL        INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

The Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/742,925, entitled SURGICAL        END EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/742,941, entitled SURGICAL        END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES;    -   U.S. patent application Ser. No. 14/742,914, entitled MOVABLE        FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/742,900, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM        STRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION        SUPPORT;    -   U.S. patent application Ser. No. 14/742,885, entitled DUAL        ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE        SURGICAL INSTRUMENTS; and    -   U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULL        ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL        INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/640,746, entitled POWERED        SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE        LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE        TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR        MULTIPLE TISSUE TYPES;    -   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID        MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE        TISSUE COMPRESSION;    -   U.S. patent application Ser. No. 14/640,831, entitled MONITORING        SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED        SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,859, entitled TIME        DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY,        CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES;    -   U.S. patent application Ser. No. 14/640,817, entitled        INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/640,844, entitled CONTROL        TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH        SELECT CONTROL PROCESSING FROM HANDLE;    -   U.S. patent application Ser. No. 14/640,837, entitled SMART        SENSORS WITH LOCAL SIGNAL PROCESSING;    -   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR        DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A        SURGICAL STAPLER;    -   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND        POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT; and    -   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL        INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION;    -   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL        APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER        OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE        BAND;    -   U.S. patent application Ser. No. 14/633,560, entitled SURGICAL        CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE        BATTERIES;    -   U.S. patent application Ser. No. 14/633,566, entitled CHARGING        SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A        BATTERY;    -   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR        MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED;    -   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED        BATTERY FOR A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/633,548, entitled POWER        ADAPTER FOR A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE        SURGICAL INSTRUMENT HANDLE;    -   U.S. patent application Ser. No. 14/633,541, entitled MODULAR        STAPLING ASSEMBLY; and    -   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL        APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND        MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING;    -   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS;    -   U.S. patent application Ser. No. 14/575,139, entitled DRIVE        ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 14/575,148, entitled LOCKING        ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE        SURGICAL END EFFECTORS;    -   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL        INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A        DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE;    -   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL        INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING        BEAM SUPPORT ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING        BEAM SUPPORT ARRANGEMENTS;    -   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM;        and    -   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/782,295, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR        SIGNAL COMMUNICATION, now U.S. Paten Application Publication No.        2014/0246471;    -   U.S. patent application Ser. No. 13/782,323, entitled ROTARY        POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2014/0246472;    -   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL        SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2014/0249557;    -   U.S. patent application Ser. No. 13/782,499, entitled        ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT,        now U.S. Patent Application Publication No. 2014/0246474;    -   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE        PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Patent Application Publication No. 2014/0246478;    -   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK        SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Paten        Application Publication No. 2014/0246477;    -   U.S. patent application Ser. No. 13/782,481, entitled SENSOR        STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now        U.S. Patent Application Publication No. 2014/0246479;    -   U.S. patent application Ser. No. 13/782,518, entitled CONTROL        METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT        PORTIONS, now U.S. Patent Application Publication No.        2014/0246475;    -   U.S. patent application Ser. No. 13/782,375, entitled ROTARY        POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM,        now U.S. Patent Application Publication No. 2014/0246473; and    -   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL        INSTRUMENT SOFT STOP, now U.S. Paten Application Publication No.        2014/0246476.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 13/803,097, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now        U.S. Paten Application Publication No. 2014/0263542;    -   U.S. patent application Ser. No. 13/803,193, entitled CONTROL        ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0263537;    -   U.S. patent application Ser. No. 13/803,053, entitled        INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL        INSTRUMENT, now U.S. Patent Application Publication No.        2014/0263564;    -   U.S. patent application Ser. No. 13/803,086, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION        LOCK, now U.S. Patent Application Publication No. 2014/0263541;    -   U.S. patent application Ser. No. 13/803,210, entitled SENSOR        ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263538;    -   U.S. patent application Ser. No. 13/803,148, entitled        MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Paten        Application Publication No. 2014/0263554;    -   U.S. patent application Ser. No. 13/803,066, entitled DRIVE        SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2014/0263565;    -   U.S. patent application Ser. No. 13/803,117, entitled        ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263553;    -   U.S. patent application Ser. No. 13/803,130, entitled DRIVE        TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Patent Application Publication No. 2014/0263543; and    -   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND        SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Paten        Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL        SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Paten Application        Publication No. 2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/226,106, entitled POWER        MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2015/0272582;    -   U.S. patent application Ser. No. 14/226,099, entitled        STERILIZATION VERIFICATION CIRCUIT, now U.S. Paten Application        Publication No. 2015/0272581;    -   U.S. patent application Ser. No. 14/226,094, entitled        VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now        U.S. Patent Application Publication No. 2015/0272580;    -   U.S. patent application Ser. No. 14/226,117, entitled POWER        MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE        UP CONTROL, now U.S. Paten Application Publication No.        2015/0272574;    -   U.S. patent application Ser. No. 14/226,075, entitled MODULAR        POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES,        now U.S. Patent Application Publication No. 2015/0272579;    -   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK        ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2015/0272569;    -   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL        INSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Paten        Application Publication No. 2015/0272571;    -   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL        INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S.        Patent Application Publication No. 2015/0272578;    -   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL        INSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent        Application Publication No. 2015/0272570;    -   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE        SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS, now U.S. Paten        Application Publication No. 2015/0272572;    -   U.S. patent application Ser. No. 14/226,133, entitled MODULAR        SURGICAL INSTRUMENT SYSTEM, now U.S. Paten Application        Publication No. 2015/0272557;    -   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS        AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Paten        Application Publication No. 2015/0277471;    -   U.S. patent application Ser. No. 14/226,076, entitled POWER        MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE        PROTECTION, now U.S. Patent Application Publication No.        2015/0280424;    -   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL        STAPLING INSTRUMENT SYSTEM, now U.S. Paten Application        Publication No. 2015/0272583; and    -   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL        INSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Paten        Application Publication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY        AND SENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066912;    -   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT        WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S.        Patent Application Publication No. 2016/0066914;    -   U.S. patent application Ser. No. 14/478,908, entitled MONITORING        DEVICE DEGRADATION BASED ON COMPONENT EVALUATION, now U.S.        Patent Application Publication No. 2016/0066910;    -   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE        SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR        INTERPRETATION, now U.S. Paten Application Publication No.        2016/0066909;    -   U.S. patent application Ser. No. 14/479,110, entitled USE OF        POLARITY OF HALL MAGNET DETECTION TO DETECT MISLOADED CARTRIDGE,        now U.S. Patent Application Publication No. 2016/0066915;    -   U.S. patent application Ser. No. 14/479,098, entitled SMART        CARTRIDGE WAKE UP OPERATION AND DATA RETENTION, now U.S. Patent        Application Publication No. 2016/0066911;    -   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE        MOTOR CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066916; and    -   U.S. patent application Ser. No. 14/479,108, entitled LOCAL        DISPLAY OF TISSUE PARAMETER STABILIZATION, now U.S. Paten        Application Publication No. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR        DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now        U.S. Patent Application Publication No. 2014/0305987;    -   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL        INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE        OPERATED FROM THE SAME ROTATABLE OUTPUT, now U.S. Paten        Application Publication No. 2014/0305989;    -   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL        INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE        OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Paten Application        Publication No. 2014/0305988;    -   U.S. patent application Ser. No. 14/248,588, entitled POWERED        LINEAR SURGICAL STAPLER, now U.S. Paten Application Publication        No. 2014/0309666;    -   U.S. patent application Ser. No. 14/248,591, entitled        TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S.        Patent Application Publication No. 2014/0305991;    -   U.S. patent application Ser. No. 14/248,584, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR        ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS,        now U.S. Patent Application Publication No. 2014/0305994;    -   U.S. patent application Ser. No. 14/248,587, entitled POWERED        SURGICAL STAPLER, now U.S. Paten Application Publication No.        2014/0309665;    -   U.S. patent application Ser. No. 14/248,586, entitled DRIVE        SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0305990; and    -   U.S. patent application Ser. No. 14/248,607, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION        ARRANGEMENTS, now U.S. Patent Application Publication No.        2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Provisional Patent Application Ser. No. 61/812,365,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR;    -   U.S. Provisional Patent Application Ser. No. 61/812,376,        entitled LINEAR CUTTER WITH POWER;    -   U.S. Provisional Patent Application Ser. No. 61/812,382,        entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;    -   U.S. Provisional Patent Application Ser. No. 61/812,385,        entitled SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION        MOTORS AND MOTOR CONTROL; and    -   U.S. Provisional Patent Application Ser. No. 61/812,372,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich first jaw is pivotable relative to the second jaw. The surgicalstapling system further comprises an articulation joint configured topermit the end effector to be rotated, or articulated, relative to theshaft. The end effector is rotatable about an articulation axisextending through the articulation joint. Other embodiments areenvisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

Handle Assembly

FIG. 1 depicts a motor-driven surgical system 10 that may be used toperform a variety of different surgical procedures. In the illustratedembodiment, the motor driven surgical system 10 comprises a selectivelyreconfigurable housing or handle assembly 20 that is attached to oneform of an interchangeable surgical tool assembly 1000. For example, thesystem 10 that is depicted in FIG. 1 includes an interchangeablesurgical tool assembly 1000 that comprises a surgical cutting andfastening instrument which may be referred to as an endocutter. As willbe discussed in further detail below, the interchangeable surgical toolassemblies may include end effectors that are adapted to supportdifferent sizes and types of staple cartridges and, have different shaftlengths, sizes, and types, etc. Such arrangements, for example, mayutilize any suitable fastener, or fasteners, to fasten tissue. Forinstance, a fastener cartridge comprising a plurality of fastenersremovably stored therein can be removably inserted into and/or attachedto the end effector of a surgical tool assembly. Other surgical toolassemblies may be interchangeably employed with the handle assembly 20.For example, the interchangeable surgical tool assembly 1000 may bedetached from the handle assembly 20 and replaced with a differentsurgical tool assembly that is configured to perform other surgicalprocedures. In other arrangements, the surgical tool assembly may not beinterchangeable with other surgical tool assemblies and essentiallycomprise a dedicated shaft that is non-removably affixed or coupled tothe handle assembly 20, for example. The surgical tool assemblies mayalso be referred to as elongate shaft assemblies. The surgical toolassemblies may be reusable or, in other configurations, the surgicaltool assemblies may be designed to be disposed of after a single use.

As the present Detailed Description proceeds, it will be understood thatthe various forms of interchangeable surgical tool assemblies disclosedherein may also be effectively employed in connection withrobotically-controlled surgical systems. Thus, the terms “housing” and“housing assembly” may also encompass a housing or similar portion of arobotic system that houses or otherwise operably supports at least onedrive system that is configured to generate and apply at least onecontrol motion which could be used to actuate the elongate shaftassemblies disclosed herein and their respective equivalents. The term“frame” may refer to a portion of a handheld surgical instrument. Theterm “frame” may also represent a portion of a robotically controlledsurgical instrument and/or a portion of the robotic system that may beused to operably control a surgical instrument. For example, thesurgical tool assemblies disclosed herein may be employed with variousrobotic systems, instruments, components and methods such as, but notlimited to, those disclosed in U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Patent Application Publication No.2012/0298719 which is hereby incorporated by reference herein in itsentirety.

Referring now to FIGS. 1 and 2, the housing assembly or handle assembly20 comprises a primary housing portion 30 that may be formed from a pairof housing segments 40, 70 that may be fabricated from plastic, polymermaterials, metal, etc. and be joined together by an appropriate fastenerarrangement such as, for example, adhesive, screws, press-fit features,snap-fit features, latches, etc. As will be discussed in further detailbelow, the primary housing portion 30 operably supports a plurality ofdrive systems therein that are configured to generate and apply variouscontrol motions to corresponding portions of the interchangeablesurgical tool assembly that is operably attached thereto. The handleassembly 20 further comprises a grip portion 100 that is movably coupledto the primary housing portion 30 and is configured to be gripped andmanipulated by the clinician in various positions relative to theprimary housing portion 30. The grip portion 100 may be fabricated froma pair of grip segments 110, 120 that may be fabricated from plastic,polymer materials, metal, etc. and are joined together by an appropriatefastener arrangement such as, for example, adhesive, screws, press-fitfeatures, snap-fit features, latches, etc. for assembly and maintenancepurposes.

As can be seen in FIG. 2, the grip portion 100 comprises a grip housing130 that defines a hollow cavity 132 that is configured to operablysupport a drive motor and gearbox which will be discussed in furtherdetail below. The upper portion 134 of the grip housing 130 isconfigured to extend through an opening 80 in the primary housingportion 30 and be pivotally journaled on a pivot shaft 180. The pivotshaft 180 defines a pivot axis designated as “PA”. See FIG. 3. Forreference purposes, the handle assembly 20 defines a handle axisdesignated as “HA” that may be parallel to the shaft axis “SA” of theelongate shaft assembly of the interchangeable surgical tool that isoperably attached to the handle assembly 20. The pivot axis PA istransverse to the handle axis HA. See FIG. 1. Such arrangement enablesthe grip portion 100 to be pivoted relative to the primary housingportion 30 about the pivot axis PA to a position that is best suited forthe type of interchangeable surgical tool assembly that is coupled tothe handle assembly 20. The grip housing 130 defines a grip axis,generally designated as “GA”. See FIG. 2. When the interchangeablesurgical tool assembly that is coupled to the handle assembly 20comprises an endocutter for example, the clinician might want toposition the grip portion 100 relative to the primary housing portion 30such that the grip axis GA is perpendicular or approximatelyperpendicular (angle “H1”) to the handle axis HA (referred to herein asa “first grip position”). See FIG. 5. However, if the handle assembly 20is being used to control an interchangeable surgical tool assembly thatcomprises a circular stapler for example, the clinician may wish topivot the grip portion 100 relative to the primary housing portion 30 toa position wherein the grip axis GA is at a forty-five degree orapproximately forty-five degree angle or other suitable acute angle(angle “H2”) relative to the handle axis HA. This position is referredto herein as a “second grip position”. FIG. 5 illustrates the gripportion 100 in phantom lines in the second grip position.

Referring now to FIGS. 3-5, the handle assembly 20 also includes a griplocking system, generally designated as 150, for selectively locking thegrip portion 100 in the desired orientation relative to the primaryhousing portion 30. In one arrangement, the grip locking system 150comprises an arcuate series 152 of pointed teeth 154. The teeth 154 arespaced from each other and form a locking groove 156 therebetween. Eachlocking groove 156 corresponds to a particular angular locking positionfor the grip portion 100. For example, in at least one arrangement, theteeth 154 and locking grooves or “locking locations” 156 are arranged topermit the grip portion 100 to be locked at 10-15 degree intervalsbetween the first grip position and the second grip position. Thearrangement may employ two stop positions which are tailored to the typeof instrument (shaft arrangement) employed. For example, for anendocutter shaft arrangement, it may be approximately around ninetydegrees to the shaft and for a circular stapler arrangement, the anglemay be approximately forty-five degrees to the shaft while being sweptforward towards the surgeon. The grip locking system 150 furtherincludes a locking button 160 that has a locking portion that isconfigured to lockingly engage the locking grooves 156. For example, thelocking button 160 is pivotally mounted in the primary handle portion 30on a pivot pin 131 to permit the locking button 160 to pivot intoengagement with a corresponding locking groove 156. A locking spring 164serves to bias the locking button 160 into an engaged or locked positionwith the corresponding locking groove 156. The locking portion and theteeth configurations serve to enable the teeth 154 to slide past thelocking portion when the clinician depresses the locking button 160.Thus, to adjust the angular position of the grip portion 100 relative tothe primary housing portion 30, the clinician depresses the lockingbutton 160 and then pivots the grip portion 100 to the desired angularposition. Once the grip portion 100 has been moved to the desiredposition, the clinician releases the locking button 160. The lockingspring 164 will then bias the locking button 160 toward the series ofteeth 154 so that the locking portion enters the corresponding lockinggroove 156 to retain the grip portion 100 in that position during use.

Drive Systems

The handle assembly 20 operably supports a first rotary drive system300, a second rotary drive system 320 and a third axial drive system400. The rotary drive systems 300, 320 are each powered by a motor 200that is operably supported in the grip portion 100. As can be seen inFIG. 2, for example, the motor 200 is supported within the cavity 132 inthe grip portion 100 and has a gear box assembly 202 that has an outputdrive shaft 204 protruding therefrom. In various forms, the motor 200may be a DC brushed driving motor having a maximum rotation of,approximately, 25,000 RPM, for example. In other arrangements, the motormay include a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. The motor 200 maybe powered by a power source 210 that, in one form, may comprise aremovable power pack 212. The power source 210 may comprise, forexample, anyone of the various power source arrangements disclosed infurther detail in U.S. Paten Application Publication No. 2015/0272575and entitled SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM, the entiredisclosure of which is hereby incorporated by reference herein. In theillustrated arrangement, for example, the power pack 212 may comprise aproximal housing portion 214 that is configured for attachment to adistal housing portion 216. The proximal housing portion 214 and thedistal housing portion 216 are configured to operably support aplurality of batteries 218 therein. Batteries 218 may each comprise, forexample, a Lithium Ion (“LI”) or other suitable battery. The distalhousing portion 216 is configured for removable operable attachment to ahandle circuit board assembly 220 which is also operably coupled to themotor 200. The handle circuit board assembly 220 may also be generallyreferred to herein as the “control system or CPU 224”. A number ofbatteries 218 may be connected in series may be used as the power sourcefor the handle assembly 20. In addition, the power source 210 may bereplaceable and/or rechargeable. In other embodiments, the surgicalinstrument 10 may be powered by alternating current (AC) for example.The motor 200 may be controlled by a rocker switch 206 that is mountedto the grip portion 100.

As outlined above, the motor 200 is operably coupled to a gear boxassembly 202 that includes an output drive shaft 204. Attached to theoutput drive shaft 204 is a driver bevel gear 230. The motor 200, thegear box assembly 202, the output drive shaft 204 and the driver bevelgear 230 may also be collectively referred to herein as a “motorassembly 231”. The driver bevel gear 230 interfaces with a driven bevelgear 234 that is attached to a system drive shaft 232 as well as a pivotbevel gear 238 that is journaled on the pivot shaft 180. The drivenbevel gear 234 is axially movable on the system drive shaft 232 betweenan engaged position wherein the driven bevel gear 234 is in meshingengagement with the driver bevel gear 230 (FIG. 5) and a disengagedposition wherein the driven bevel gear 234 is out of meshing engagementwith the drive bevel gear 230 (FIG. 14). A drive system spring 235 isjournaled between the driven bevel gear 234 and a proximal end flange236 that is formed on a proximal portion of the system drive shaft 232.See FIGS. 4 and 14. The drive system spring 235 serves to bias thedriven bevel gear 234 out of meshing engagement with the driver bevelgear 230 as will be discussed in further detail below. The pivot bevelgear 238 facilitates pivotal travel of the output drive shaft 204 anddriver bevel gear 230 with the grip portion 100 relative to the primaryhandle portion 30.

In the illustrated example, the system drive shaft 232 interfaces with arotary drive selector system, generally designated as 240. In at leastone form, for example, the rotary drive selector system 240 comprises ashifter gear 250 that is selectively movable between the first rotarydrive system 300 and the second rotary drive system 320. As can be seenin FIGS. 6-9, for example, the drive selector system 240 comprises ashifter mounting plate 242 that is non-movably mounted within primaryhandle portion 30. For example, the shifter mounting plate 242 may befrictionally retained between mounting lugs (not shown) formed in thehousing segments 40, 70 or be otherwise retained therein by screws,adhesive, etc. Still referring to FIGS. 6-9, the system drive shaft 232extends through a hole in the shifter mounting plate 242 and has thecentral, or system, drive gear 237 non-rotatably attached thereto. Forexample the central drive gear 237 may be attached to the system driveshaft 232 by a keyway arrangement 233. See FIGS. 6-9. In otherarrangements, the system drive shaft 232 may be rotatably supported inthe shifter mounting plate 242 by a corresponding bearing (not shown)that is mounted thereto. In any event, rotation of the system driveshaft 232 will result in rotation of the central drive gear 234.

As can be seen in FIG. 3, the first drive system 300 includes a firstdrive socket 302 that is rotatably supported in a distal wall 32 formedin the primary handle portion 30. The first drive socket 302 maycomprise a first body portion 304 that has a splined socket formedtherein. A first driven gear 306 is formed on or is non-movably attachedto the first body portion 304. The first body portion 304 may berotatably supported in a corresponding hole or passage provided thedistal wall 32 or it may be rotatably supported in a correspondingbearing (not shown) that is mounted in the distal wall 32. Similarly,the second rotary drive system 320 includes a second drive socket 322that is also rotatably supported in the distal wall 32 of the primaryhandle portion 30. The second drive socket 322 may comprise a secondbody portion 324 that has a splined socket formed therein. A seconddriven gear 326 is formed on or is non-rotatably mounted to the secondbody portion 324. The second body portion 324 may be rotatably supportedin a corresponding hole or passage provided the distal wall 32 or it maybe rotatably supported in a corresponding bearing (not shown) that ismounted in the distal wall 32. The first and second drive sockets 302,322 are spaced from each other on each lateral side of the handle axisHA. See FIG. 4, for example.

As indicated above, in the illustrated example, the rotary driveselector system 240 includes a shifter gear 250. As can be seen in FIGS.6-9, the shifter gear 250 is rotatably mounted on an idler shaft 252that is movably supported in an arcuate slot 244 in the shifter mountingplate 242. The shifter gear 250 is mounted so as to freely rotate on theidler shaft 252 and remain in meshing engagement with the central drivegear 234. The idler shaft 252 is coupled to an end of a shaft 262 of ashifter solenoid 260. The shifter solenoid 260 is pinned or otherwisemounted with the primary handle housing 30 such that when the shiftersolenoid 260 is actuated, the shifter gear 250 is moved into meshingengagement with one of the first driven gear 306 or the second drivengear 326. For example, in one arrangement, when the solenoid shaft is262 is retracted (FIGS. 6 and 7), the shifter gear 250 is in meshingengagement with the central drive gear 234 and the first driven gear 306such that actuation of the motor 200 will result in rotation of thefirst drive socket 302. As can be seen in FIGS. 6 and 7, a shifterspring 266 may be employed to bias the shifter gear 250 into that firstactuation position. Thus, should power be lost to the surgicalinstrument 10, the shifter spring 266 will automatically bias theshifter gear 250 into the first position. When the shifter gear 250 isin that position, subsequent actuation of the motor 200 will result inrotation of the first drive socket 302 of the first rotary drive system300. When the shifter solenoid is actuated, the shifter gear 250 ismoved into meshing engagement with the second driven gear 326 on thesecond drive socket 322. Thereafter, actuation of the motor 200 willresult in actuation or rotation of the second drive socket 322 of thesecond rotary drive system 320.

Bailout System

As will be discussed in further detail below, the first and secondrotary drive systems 300, 320 may be used to power various componentportions of the interchangeable surgical tool assembly that is coupledthereto. As indicated above, in at least one arrangement, if during theactuation of the interchangeable surgical tool assembly, power was lostto the motor, the shifter spring 266 will bias the shifter gear 250 tothe first position. Depending upon which component portion of theinterchangeable surgical tool assembly was being operated, it may benecessary to reverse the application of the rotary drive motion to thefirst drive system 300 to enable the interchangeable surgical toolassembly to be removed from the patient. The handle assembly 20 of theillustrated example employs a manually actuatable “bailout” system,generally designated as 330, for manually applying a rotary drive motionto the first rotary drive system 300 in the above described scenario,for example.

Referring now to FIGS. 3, 10 and 11, the illustrated bailout system 330comprises a bailout drive train 332 that includes a planetary gearassembly 334. In at least one form, the planetary gear assembly 334includes a planetary gear housing 336 that houses a planetary geararrangement (not shown) that includes a planetary bevel gear 338. Theplanetary gear assembly 334 includes a bailout drive shaft 340 that isoperably coupled to the planetary gear arrangement within the planetarygear housing 336. Rotation of the planetary bevel gear 338 rotates theplanetary gear arrangement which ultimately rotates the bailout driveshaft 340. A bailout drive gear 342 is journaled on the bailout driveshaft 340 so that the bailout drive gear 342 can move axially on thebailout drive shaft 340, yet rotate therewith. The bailout drive gear342 is movable between a spring stop flange 344 that is formed on thebailout drive shaft 340 and a shaft end stop 346 that is formed on thedistal end of the bailout drive shaft 340. A bailout shaft spring 348 isjournaled on the bailout drive shaft 340 between the bailout drive gear342 and the spring stop flange 344. The bailout shaft spring 348 biasesthe bailout drive gear 342 distally on the bailout drive shaft 340. Whenthe bailout drive gear 342 is in its distal-most position on the bailout drive shaft 340, it is in meshing engagement with a bailout drivengear 350 that is non-rotatably mounted to the system drive shaft 232.See FIG. 14.

Referring now to FIGS. 12 and 13, the bailout system 330 includes abailout actuator assembly or bailout handle assembly 360 thatfacilitates the manual application of a bailout drive motion to thebailout drive train 332. As can be seen in those Figures, the bailouthandle assembly 360 includes a bailout bevel gear assembly 362 thatcomprises a bailout bevel gear 364 and a ratchet gear 366. The bailouthandle assembly 360 further includes a bailout handle 370 that ismovably coupled to the bailout bevel gear assembly 362 by a pivot yoke372 that is pivotally mounted on the ratchet gear 366. The bailouthandle 370 is pivotally coupled to the pivot yoke 372 by a pin 374 forselective pivotal travel between a stored position “SP” and an actuationposition “AP”. See FIG. 12. A handle spring 376 is employed to bias thebailout handle 370 into the actuation position AP. In at least onearrangement, the angle between the axis SP representing the storedposition and the axis AP representing the actuation position may beapproximately thirty degrees, for example. See FIG. 13. As can also beseen in FIG. 13, the bailout handle assembly 360 further includes aratchet pawl 378 that is rotatably mounted in a cavity or hole 377 inthe pivot yoke 372. The ratchet pawl 378 is configured to meshinglyengage the ratchet gear 366 when rotated in an actuation direction “AD”and then rotate out of meshing engagement when rotated in the oppositedirection. A ratchet spring 384 and ball member 386 are movablysupported in a cavity 379 in the pivot yoke 372 and serve to lockinglyengage detents 380, 382 in the ratchet pawl 378 as the bailout handle370 is actuated (ratcheted).

Referring now to FIGS. 3 and 10, the bailout system 330 further includesa bailout access panel 390 that is maneuverable between an open positionand a closed position. In the illustrated arrangement, the bailoutaccess panel 390 is configured to be removably coupled to the housingsegment 70 of the primary housing portion 30. Thus, in at least thatembodiment, when the bailout access panel 390 is removed or detachedfrom the primary housing portion 30, it is said to be in an “open”position and when the bailout access panel 390 is attached to theprimary housing portion 30 as illustrated, it is said to be in a“closed” position. Other embodiments are contemplated, however, whereinthe access panel is movably coupled to the primary housing portion suchthat when the access panel is in the open position, it remains attachedthereto. For example, in such embodiments, the access panel may bepivotally attached to the primary housing portion or slidably attachedto the primary housing portion and be maneuverable between an openposition and a closed position. In the illustrated example, the bailoutaccess panel 390 is configured to snappingly engage correspondingportions of the housing segment 70 to removably retain it in a “closed”position. Other forms of mechanical fasteners such as screws, pins, etc.could also be used.

Regardless of whether the bailout access panel 390 is detachable fromthe primary housing portion 30 or it remains movably attached to theprimary housing portion 30, the bailout access panel 390 includes adrive system locking member or yoke 392 and a bailout locking member oryoke 396 that each protrudes out from the backside thereof or areotherwise formed thereon. The drive system locking yoke 392 includes adrive shaft notch 394 that is configured to receive a portion of thesystem drive shaft 232 therein when the bailout access panel 390 isinstalled in the primary housing portion 30 (i.e., the bailout accesspanel is in the “closed” position). When the bailout access panel 390 ispositioned or installed in the closed position, the drive system lockingyoke 392 serves to bias the driven bevel gear 234 into meshingengagement with the driver bevel gear 230 (against the bias of the drivesystem spring 235). In addition, the bailout locking yoke 396 includes abailout drive shaft notch 397 that is configured to receive a portion ofthe bailout drive shaft 340 therein when the bailout access panel 390 isinstalled or positioned in the closed position. As can be seen in FIGS.5 and 10, the bailout locking yoke 396 also serves to bias the bailoutdrive gear 342 out of meshing engagement with the bailout driven gear350 (against the bias of the bailout shaft spring 348). Thus, thebailout locking yoke 396 prevents the bailout drive gear 342 frominterfering with rotation of the system drive shaft 232 when the bailoutaccess panel 390 is installed or in the closed position. In addition,the bailout locking yoke 396 includes a handle notch 398 for engagingthe bailout handle 370 and retaining it in the stored position SP.

FIGS. 4, 5 and 10 illustrate the configurations of the drive systemcomponents and the bailout system components when the bailout accesspanel 390 is installed or is in the closed position. As can be seen inthose Figures, the drive system locking member 392 biases the drivenbevel gear 234 into meshing engagement with the driver bevel gear 230.Thus, when the bailout access panel 390 is installed or is in the closedposition, actuation of the motor 200 will result in the rotation of thedriver bevel gear 230 and ultimately the system drive shaft 232. Also,when in that position, the bailout locking yoke 396 serves to bias thebailout drive gear 342 out of meshing engagement with the bailout drivengear 350 on the system drive shaft 232. Thus, when the bailout accesspanel 390 is installed or is in the closed position, the drive system isactuatable by the motor 200 and the bailout system 330 is disconnectedor prevented from applying any actuation motion to the system driveshaft 232. To activate the bailout system 330, the clinician firstremoves the bailout access panel 390 or otherwise moves the bailoutaccess panel 390 to the open position. This action removes the drivesystem locking member 392 from engagement with the driven bevel gear 234which thereby permits the drive system spring 235 to bias the drivenbevel gear 234 out of meshing engagement with the driver bevel gear 230.In addition, removal of the bailout access panel 390 or movement of thebailout access panel to an open position also results in thedisengagement of the bailout locking yoke 396 with the bailout drivegear 342 which thereby permits the bailout shaft spring 348 to bias thebailout drive gear 342 into meshing engagement with the bailout drivengear 350 on the system drive shaft 232. Thus, rotation of the bailoutdrive gear 342 will result in rotation of the bailout driven gear 350and the system drive shaft 232. Removal of the bailout access panel 390or otherwise movement of the bailout access panel 390 to an openposition also permits the handle spring 376 to bias the bailout handle370 into the actuation position shown in FIGS. 11 and 14. When in thatposition, the clinician can manually ratchet the bailout handle 370 inthe ratchet directions RD which results in the rotation of the of theratchet bevel gear 364 (in a clockwise direction in FIG. 14, forexample) which ultimately results in the application of a retractionrotary motion to the system drive shaft 232 through the bailout drivetrain 332. The clinician may ratchet the bailout handle 370 a number oftimes until the system drive shaft 232 has been sufficiently rotated anumber of times to retract a component of the surgical end effectorportion of the surgical tool assembly that is attached to the handleassembly 20. Once the bailout system 330 has been sufficiently manuallyactuated, the clinician may then replace the bailout access panel 390(i.e., return the bailout access panel 390 to the closed position) tothereby cause the drive system locking member 392 to bias the drivenbevel gear 234 into meshing engagement with the driver bevel gear 230and the bailout locking yoke 396 to bias the bailout drive gear 342 outof meshing engagement with the bailout driven gear 350. As was discussedabove, should power be lost or interrupted, the shifter spring 266 willbias the shifter solenoid 260 into the first actuation position. Assuch, actuation of the bailout system 330 will result in the applicationof reversing or retraction motions to the first rotary drive system 300.

As discussed above, a surgical stapling instrument can comprise amanually-actuated bailout system configured to retract a staple firingdrive, for example. In many instances, the bailout system may need to beoperated and/or cranked more than one time to fully retract the staplefiring drive. In such instances, the user of the stapling instrument maylose track of how many times they have cranked the bailout and/orotherwise become confused as to how much further the firing drive needsto be retracted. Various embodiments are envisioned in which thestapling instrument comprises a system configured to detect the positionof a firing member of the firing drive, determine the distance in whichthe firing member needs to be retracted, and display that distance tothe user of the surgical instrument.

In at least one embodiment, a surgical stapling instrument comprises oneor more sensors configured to detect the position of the firing member.In at least one instance, the sensors comprise Hall Effect sensors, forexample, and can be positioned in a shaft and/or end effector of thestapling instrument. The sensors are in signal communication with acontroller of the surgical stapling instrument which is, in turn, insignal communication with a display on the surgical stapling instrument.The controller comprises a microprocessor configured to compare theactual position of the firing member to a datum, or reference,position—which comprises a fully retracted position of the firingmember—and calculate the distance, i.e., the remaining distance, betweenthe actual position of the firing member and the reference position.

Further to the above, the display comprises an electronic display, forexample, and the controller is configured to display the remainingdistance on the electronic display in any suitable manner. In at leastone instance, the controller displays a progress bar on the display. Insuch instances, an empty progress bar can represent that the firingmember is at the end of its firing stroke and a full progress bar canrepresent that the firing member has been fully retracted, for example.In at least one instance, 0% can represent that the firing member is atthe end of its firing stroke and 100% can represent that the firingmember has been fully retracted, for example. In certain instances, thecontroller is configured to display how many actuations of the bailoutmechanism are required to retract the firing member to its fullyretracted position on the display.

Further to the above, the actuation of the bailout mechanism canoperably disconnect a battery, or power source, of the surgical staplinginstrument from an electric motor of the firing drive. In at least oneembodiment, the actuation of the bailout mechanism flips a switch whichelectrically decouples the battery from the electric motor. Such asystem would prevent the electric motor from resisting the manualretraction of the firing member.

The illustrated handle assembly 20 also supports a third axial drivesystem that is generally designated as 400. As can be seen in FIGS. 3and 4, the third axial drive system 400, in at least one form, comprisesa solenoid 402 that has a third drive actuator member or rod 410protruding therefrom. The distal end 412 of the third drive actuatormember 410 has a third drive cradle or socket 414 formed therein forreceiving a corresponding portion of a drive system component of aninterchangeable surgical tool assembly that is operably attachedthereto. The solenoid 402 is wired to or otherwise communicates with thehandle circuit board assembly 220 and the control system or CPU 224. Inat least one arrangement, the solenoid 402 is “spring loaded” such thatwhen the solenoid 402 is unactuated, the spring component thereof biasesthe third drive actuator 410 back to an unactuated starting position.

As indicated above, the reconfigurable handle assembly 20 may beadvantageously employed to actuate a variety of differentinterchangeable surgical tool assemblies. To that end, the handleassembly 20 includes a tool mounting portion that is generallydesignated as 500 for operably coupling an interchangeable surgical toolassembly thereto. In the illustrated example, the tool mounting portion500 includes two inwardly facing dovetail receiving slots 502 that areconfigured to engage corresponding portions of a tool attachment moduleportion of the interchangeable surgical tool assembly. Each dovetailreceiving slot 502 may be tapered or, stated another way, be somewhatV-shaped. The dovetail receiving slots 502 are configured to releasablyreceive corresponding tapered attachment or lug portions that are formedon a portion of the tool attachment nozzle portion of theinterchangeable surgical tool assembly. Each interchangeable surgicaltool assembly may also be equipped with a latching system that isconfigured to releasable engage corresponding retention pockets 504 thatare formed in the tool mounting portion 500 of the handle assembly 20.

The various interchangeable surgical tool assemblies may have a“primary” rotary drive system that is configured to be operably coupledto or interface with the first rotary drive system 310 as well as a“secondary” rotary drive system that is configured to be operablycoupled to or interface with the second rotary drive system 320. Theprimary and secondary rotary drive systems may be configured to providevarious rotary motions to portions of the particular type of surgicalend effector that comprises a portion of the interchangeable surgicaltool assembly. To facilitate operable coupling of the primary rotarydrive system to the first rotary drive system and the secondary drivesystem to the second rotary drive system 320, the tool mounting portion500 of the handle assembly 20 also includes a pair of insertion ramps506 that are configured to bias portions of the primary and secondaryrotary drive systems of the interchangeable surgical tool assemblydistally during the coupling process so as to facilitate alignment andoperable coupling of the primary rotary drive system to the first rotarydrive system 300 on the handle assembly 20 and the secondary rotarydrive system to the second rotary drive system 320 on the handleassembly 20.

The interchangeable surgical tool assembly may also include a “tertiary”axial drive system for applying axial motion(s) to correspondingportions of the surgical end effector of the interchangeable surgicaltool assembly. To facilitate operable coupling of the tertiary axialdrive system to the third axial drive system 400 on the handle assembly20, the third drive actuator member 410 is provided with a socket 414that is configured to operably receive a lug or other portion of thetertiary axial drive system therein.

Interchangeable Surgical Tool Assembly

FIG. 15 illustrates use of an interchangeable surgical tool assembly1000 that may be used in connection with the handle assembly 20. As canbe seen in that Figure, for example, the interchangeable surgical toolassembly 1000 includes a tool attachment module 1010 that is configuredfor operable and removable attachment to the tool mounting portion 500of the handle assembly 20. The tool attachment module 1010 in theillustrated arrangement includes a nozzle frame 1020. In the illustratedarrangement, the interchangeable surgical tool assembly 1000 includes aprimary rotary drive system 1100 and a secondary rotary drive system1200. The primary rotary drive system 1100 is configured to operablyinterface with the first rotary drive system 300 on the handle assembly20 and apply rotary firing motions to the surgical end effector 1500attached thereto as will be discussed in further detail below. Thesecondary rotary drive system 1200 is configured to operably interfacewith the second rotary drive system 320 on the handle assembly 20 andapply articulation control motions to an articulation system 1700. Thearticulation system 1700 couples the surgical end effector 1500 to anelongate shaft assembly 1400 that is coupled to the nozzle frame 1020.The interchangeable surgical tool assembly 1000 further includes atertiary drive system 1300 that is configured to operably interface withthe third axial drive system 400 in the handle assembly 20. The tertiaryaxial drive system 1300 of the surgical tool assembly comprises atertiary actuation shaft 1302 that has a shaft attachment lug 1306formed on the proximal end 1304 thereof. As will be discussed in furtherdetail below, when the interchangeable surgical tool assembly 1000 iscoupled to the handle assembly 20, the shaft attachment lug 1306 isreceived in the shaft attachment socket 414 on the distal end 412 of thethird drive actuator member 410.

Still referring to FIG. 15, the reader will observe that the toolmounting portion 500 of the handle assembly 20 includes two inwardlyfacing dovetail receiving slots 502. Each dovetail receiving slot 502may be tapered or, stated another way, be somewhat V-shaped. Thedovetail receiving slots 502 are configured to releasably receivecorresponding tapered attachment or lug portions 1022 formed on thenozzle frame 1020. Turning next to FIG. 18, in at least one form, thetool attachment module 1010 is removably latched to the tool mountingportion 500 of the handle assembly 20 by a latching system generallydesignated as 1030. In the illustrated embodiment, the latching system1030 comprises a lock yoke 1032 that includes a pair of inwardlyextending pivot pins 1034 (only one is shown in FIG. 18) that arereceived in corresponding pivot holes (not shown) in the nozzle frame1020. Such arrangement serves to pivotally or movably couple the lockyoke 1032 to the nozzle frame 1020. The lock yoke 1032 further includesa pair of retention lugs or hook formations 1036 (only one can be seenin FIG. 18) that are configured to be hookingly or otherwise retaininglyreceived in corresponding retention pockets 504 that are formed in thetool mounting portion 500 of the handle assembly 20. The lock yoke 1032may be pivoted out of retaining engagement by applying an unlockingmotion (represented by arrow 1041 in FIGS. 18, 20 and 21) to a releasebutton 1038 that is attached to the lock yoke 1032. A lock yoke spring1040 is received on a spring lug 1039 that is formed on the lock yoke1032 and a spring mounting lug 1021 that is formed on the nozzle frame1020. The lock yoke spring 1040 serves to bias the lock yoke 1032 intothe locked position.

The latching system 1030 of the illustrated example further comprises ashaft coupler release assembly 1031 for releasably engaging the primaryrotary drive system 1100 to the first rotary drive system 300 as well asthe secondary rotary drive system 1200 to the second rotary drive system320 on the handle assembly 20. Referring now to FIGS. 18 and 19, theprimary rotary drive system 1100 includes a primary drive key 1102 thatis configured to be axially received within the first drive socket 302of the first rotary drive system 300. The primary drive key 1102 isslidably received on a primary transfer shaft 1104 that is rotatablysupported by a bulkhead 1023 that is formed in the nozzle frame 1020.The primary drive key 1102 also movably extends through a hole 1025 inanother bulkhead 1024 that is formed in the nozzle frame 1020. See FIG.18. The primary transfer shaft 1104 is splined so that the primary drivekey 1102 is free to axially move on the primary transfer shaft 1104 butnot rotate relative thereto such that rotation of the primary drive key1102 results in rotation of the primary transfer shaft 1104. As can befurther seen in FIG. 18, the primary drive key 1102 includes anattachment flange 1106 that is received within a cavity 1044 in acoupler release tab 1042. Thus, the primary drive key 1102 and thecoupler release tab 1042 move as a unit. A primary transfer spring 1108is journaled on the primary transfer shaft 1104 and extends between thebulkhead 1023 and the coupler release tab 1042 to bias the couplerrelease tab 1042 and the primary drive key 1102 in the proximaldirection “PD” on the primary transfer shaft 1104.

Still referring to FIGS. 18 and 19, the secondary rotary drive system1200 includes a secondary drive key 1202 that is configured to beaxially received within the second drive socket 322 of the second rotarydrive system 320. The secondary drive key 1202 is slidably received on asecondary transfer shaft 1204 that is rotatably supported by thebulkhead 1023. The secondary drive key 1202 also movably extends througha hole 1026 in bulkhead 1024. The secondary transfer shaft 1204 issplined so that the secondary drive key 1202 is free to axially move onthe secondary transfer shaft 1204 but not rotate relative thereto suchthat rotation of the secondary drive key 1202 results in rotation of thesecondary transfer shaft 1204. The secondary drive key 1202 includes anattachment flange (not shown) that is received within a cavity (notshown) in the coupler release tab 1042. Thus, the secondary drive key1202 and the coupler release tab 1042 move as a unit. A secondarytransfer spring 1208 is journaled on the secondary transfer shaft 1204and extends between the bulkhead 1023 and the coupler release tab 1042to bias the coupler release tab 1042 and the secondary drive key 1202 inthe proximal direction PD on the secondary transfer shaft 1204. As canbe seen in FIG. 18, the coupler release tab 1042 is formed with twoupstanding actuator portions 1046 that correspond to inwardly extendingcoupler release tabs 1048 formed on the lock yoke 1032.

Operation of the latching system 1030 may be understood from referenceto FIGS. 20-22. FIG. 20 illustrates the beginning of the couplingprocess wherein the interchangeable surgical tool assembly 1000 is movedin the installation direction “ID” relative to the handle assembly 20.To commence the installation process, the clinician aligns the taperedattachment lugs 1022 on the nozzle frame 1020 with their correspondingdovetail slot 502 on the tool mounting portion 500 of the handleassembly 20 and moves the interchangeable surgical tool assembly 1000 inthe insertion direction ID relative to the handle assembly 20. Insertionand movement of the tapered attachment lugs 1022 in their respectivedovetail slot 502 serves to align the shaft attachment lug 1306 on thetertiary actuation shaft 1302 with the shaft attachment socket 414 onthe distal end 412 of the third drive actuator member 410. Likewise, theprimary drive key 1102 and the secondary drive key 1202 are each alignedfor contact with corresponding insertion ramps 506 that are formed onthe tool mounting portion 500 of the handle assembly 20.

FIG. 21 illustrates contact between the primary drive key 1102 and thecorresponding insertion ramp 506 with it being understood that thesecondary drive key 1202 would be in a similar position with itscorresponding insertion ramp 506. As can be seen in that Figure, theprimary drive key 1102 has contacted the insertion ramp 506 andcontinued advancement of the interchangeable surgical tool assembly 1000in the installation direction ID causes the insertion ramp 506 to biasthe primary drive key 1102 in the distal direction DD on the primarytransfer shaft 1104. The secondary drive key 1202 would similarly movein the distal direction DD on the secondary transfer shaft 1204. Thismovement may be further achieved by pushing the release button 1038 inthe direction represented by arrow 1041 which causes the lock yoke 1032to contact the coupler release tab 1042 and move it in the distaldirection DD against the biasing force of the first and second transfersprings 1108, 1208. The clinician may maintain the pressure on therelease button 1038 so that once the primary drive key 1102 andsecondary drive key 1202 clear their corresponding insertion ramps 506,the primary drive key 1102 and secondary drive key 1202 can move intoalignment with the corresponding first and second drive sockets 302,322, respectively. When the tapered attachment lugs 1022 are seated intheir respective dovetail slots 502, the primary drive key 1102 isaxially aligned with the first drive socket 302 and the secondary drivekey 1202 is axially aligned with the second drive socket 322, such thatwhen the clinician releases the release button 1038, the primary drivekey 1102 enters the first drive socket 302 and the secondary drive key1202 enters the second drive socket 322. See FIG. 22. Thus, rotation ofthe first drive socket 302 will result in rotation of the primary drivekey 1102 and the primary transfer shaft 1104 and rotation of the seconddrive socket 322 will result in rotation of the secondary drive key 1202and the secondary transfer shaft 1204. In addition, the shaft attachmentlug 1306 is received within the shaft attachment socket 414 on thedistal end 412 of the third drive actuator member 410. Thus, axialmovement of the third drive actuator member 410 will result in the axialmovement of the tertiary actuation shaft 1302. As can also be seen inFIGS. 20-22, the interchangeable surgical tool assembly 1000 furtherincludes an onboard “tool” circuit board 1060 that has a connectorportion 1062 that is configured to mate with a corresponding connector222 on the handle circuit board 220. When the tool circuit board 1060 iscoupled to the handle circuit board 220, the tool circuit board providesan identification signal to the control system or CPU 224 so that thecontrol system or CPU 224 can select the appropriate control actions forthe type of interchangeable surgical tool assembly that is beingemployed.

End Effectors

The interchangeable surgical tool assembly 1000 includes a surgical endeffector 1500 that is configured to cut and fasten tissue. As can beseen in FIGS. 23 and 24, the surgical end effector 1500 is operablycoupled to an elongate shaft assembly 1400 by an articulation joint1702. As will be discussed in further detail below, the elongate shaftassembly 1400 is operably coupled to the tool attachment module 1010 andcomprises portions of the primary rotary drive system 1100, thesecondary rotary drive system 1200 and the tertiary axial drive system1300. Referring now to FIGS. 25-28, the surgical end effector 1500includes an elongate channel 1520 that is configured to operably supporta surgical staple cartridge 1550 therein. The surgical staple cartridge1550 may comprise a compressible or implantable staple cartridge thathas a body portion 1552 that consists of a compressible hemostatmaterial such as, for example, oxidized regenerated cellulose (“ORC”) ora bio-absorbable foam in which lines of unformed metal staples or otherforms of fasteners are supported. In at least some embodiments, in orderto prevent the staple from being affected and the hemostat material frombeing activated during the introduction and positioning process, theentire cartridge may be coated and/or wrapped in a biodegradable filmsuch as a polydioxanon film, sold under the trademark PDS®, apolyglycerol sebacate (PGS) film, and/or other biodegradable filmsformed from PGA (polyglycolic acid), PCL (polycaprolactone), PLA or PLLA(polylactic acid), PHA (polyhydroxyalkanoate), PGCL (poliglecaprone 25)and/or a composite of PGA, PCL, PLA, PDS, for example, that would beimpermeable until ruptured. Varieties of different implantable cartridgearrangements are known and may be employed. For example, variousimplantable/compressible cartridge arrangements are disclosed in furtherdetail in many of the patent applications and patents that have beenincorporated by reference herein in their respective entireties. In theillustrated example, the cartridge body portion 1552 of surgical staplecartridge 1550 is sized to be removably supported within the elongatechannel 1520.

The elongate channel 1520 and surgical staple cartridge 1550 installedtherein may also be referred to herein a “first jaw” 1502. The surgicalend effector 1500 also includes a second jaw 1504 in the form of ananvil assembly 1560 that is supported for movable travel relative to thefirst jaw. Stated another way, the first and second jaws 1502 and 1504may be configured for movable travel relative to each other between openpositions and closed positions. In the illustrated arrangement, theanvil assembly 1560 comprises an anvil body portion or anvil frame 1562.The anvil frame 1562 includes a proximal anvil portion 1570 that has apair of trunnion pins 1572 extending laterally therefrom. The trunnionpins 1572 are movably received in pivot slots 1526 that are formed incorresponding upstanding walls 1524 of a channel mounting portion 1522of the elongate channel 1520. See FIGS. 27 and 28. The anvil frame 1562,in at least one form, includes a pair of downwardly extending tissuestops 1564 that serve to limit the distance in which the target tissuemay extend proximally between the first and second jaws 1502, 1504 sothat when the target tissue is severed, the fasteners are properlypositioned to fasten the cut tissue. When the first and second jaws1502, 1504 are in the closed position, the tissue stops 1564 are outsideof the upstanding walls 1524 of the channel mounting portion 1522 andthe proximal anvil portion 1570 is located between the upstanding walls1524. See FIG. 28.

Anvil Concentric Drive Member

The anvil assembly 1560 operably supports an anvil concentric drivemember 1600 for operably driving a firing member 1620 through the endeffector 1500. The anvil concentric drive member 1600 may, for example,be centrally disposed within the anvil frame 1562 and substantiallyextend the length thereof. The anvil concentric drive member 1600 in theillustrated embodiment comprises an anvil drive shaft 1610 that includesa distal bearing lug 1611 and a proximal bearing lug 1612. The distalbearing lug 1611 is rotatably housed in a distal bearing housing 1580that is supported in a bearing pocket in the anvil frame 1562. Theproximal bearing lug 1612 is rotatably supported in the anvil assembly1560 by a floating bearing housing 1582 that is movably supported in abearing pocket 1574 that is formed in the proximal anvil portion 1570.See FIG. 27. The proximal and distal bearing housing arrangements mayserve to prevent or at least minimize an occurrence of compressiveforces on the anvil drive shaft 1610 which might otherwise cause theanvil drive shaft 1610 to buckle under high force conditions. The anvildrive shaft 1610 further includes a driven firing gear 1614, a proximalthreaded or helix section 1616 and a distal threaded or helix section1618. In the illustrated arrangement, the proximal threaded section 1616has a first length “FL” and the distal threaded section 1618 has adistal length “DL” that is greater than the first length FL. In at leastone arrangement, for example, the first length FL may be approximately3-5 threads per inch using only one acme thread lead and the distallength DL may be approximately 9-15 threads per inch with 2-4 acmethread leads for more power. However, the proximal threaded section 1616and the distal threaded section 1618 may have other lengths. See FIG.31. As can be seen in FIG. 26, the pitch of the distal threaded section1618 is greater than the pitch of the proximal threaded section 1616.Stated another way, the lead of the distal threaded section 1618 isgreater than the lead of the proximal threaded section 1616. In onearrangement, the lead of the distal threaded section 1618 may beapproximately twice as large as the lead of the proximal threadedsection 1616. As can also be seen in FIG. 31, a dead space 1617 may beprovided between the proximal threaded section 1616 and the distalthreaded section 1618. In at least one example, the anvil drive shaft1610 may be fabricated in one piece from extruded gear stock.

To facilitate assembly of the various anvil components, the anvilassembly 1560 includes an anvil cap 1563 that may be attached to theanvil frame 1562 by welding, snap features, etc. In addition, the anvilassembly 1560 includes a pair of anvil plates or staple forming plates1568 that may contain various patterns of staple forming pockets orforming pockets on the bottom surfaces thereof that correspond to thestaple arrangements in the surgical staple cartridge 1550 that issupported in the elongate channel 1520. The staple forming plates 1568may be made of a metal or similar material and be welded to or otherwiseattached to the anvil frame 1562. In other arrangements, a single anvilplate that has a slot therein to accommodate a firing member may also beemployed. Such anvil plate or combination of plates may serve to improvethe overall stiffness of the anvil assembly. The anvil plate(s) may beflat and have the staple forming pockets or forming pockets “coined”therein, for example.

FIG. 29 illustrates one form of a firing member 1620 that includes abody portion 1622 that has a knife nut portion 1624 formed thereon orotherwise attached thereto. The knife nut portion 1624 is configured tobe received on the anvil drive shaft 1610. A distal thread nodule 1626and a proximal thread nodule 1628 that are configured to engage theproximal threaded section 1616 and the distal threaded section 1618 areformed in the knife nut portion 1624. The distal thread nodule 1626 isspaced from the proximal thread nodule 1628 relative to the length ofthe dead space 1617 such that when the knife nut portion 1624 spansacross the dead space 1617, the distal thread nodule 1626 is in threadedengagement with the distal threaded section 1618 and the proximal threadnodule 1628 is in threaded engagement with the proximal threaded section1616. In addition, an anvil engaging tab 1630 protrudes laterally fromopposite lateral portions of the knife nut 1624 and is oriented toengage the corresponding staple forming plate 1568 that are attached tothe anvil frame 1562. The firing member 1620 further includes a channelengaging tab 1632 that protrudes from each lateral side of the bodyportion 1622 to engage portions of the elongate channel 1520 as will bediscussed in further detail below. The firing member 1620 also includesa tissue cutting surface 1634.

Rotation of the anvil drive shaft 1610 in a first rotary direction willresult in the axial movement of the firing member 1620 from a startingposition (FIG. 35) to an ending position (FIG. 32). Similarly, rotationof the anvil drive shaft 1610 in a second rotary direction will resultin the axial retraction of the firing member 1620 from the endingposition back to the starting position. The anvil drive shaft 1610ultimately obtains rotary motion from a proximal drive shaft 1120 thatoperably interfaces with the primary transfer shaft 1104. Referringagain to FIGS. 16-18, a proximal drive gear 1110 is mounted to theprimary transfer shaft 1104 and is supported in meshing engagement witha power driven gear 1122 that is mounted to a proximal end of theproximal drive shaft 1120. The proximal drive shaft 1120 is rotatablysupported within a power shaft support tube 1124 and has a power bevelgear 1126 attached to its distal end. See FIG. 30. As indicated above,the illustrated interchangeable surgical tool assembly 1000 includes anarticulation joint 1702 that facilitates articulation of the surgicalend effector 1500. In at least one embodiment as illustrated in FIG. 30,the articulation joint 1702 comprises an articulation shaft 1704 that ismounted to a distal end of an outer spine tube 1402 of the elongateshaft assembly. In particular, the outer spine tube 1402 includes a pairof distally protruding pivot tabs 1404, 1406 that are attached to thecorresponding ends of the articulation shaft 1704 such that thearticulation shaft 1704 defines an articulation axis “A-A” that istransverse to a shaft axis “SA-SA” defined by the elongate shaftassembly 1400.

Still referring to FIG. 30, the power bevel gear 1126 is in meshingengagement with a centrally disposed power transfer gear 1128 that isrotatably journaled on the articulation shaft 1704. The primary rotarydrive system 1100 of the illustrated embodiment further includes adistal power shaft 1130 that has a distal driven gear 1132 attached tothe proximal end thereof by a screw or other fastener 1133. The distalpower shaft 1130 may also be referred to herein as a rotary output driveshaft. The distal driven gear 1132 is in meshing engagement with thecentrally disposed power transfer gear 1128. Turning next to FIGS. 31and 32, a distal drive gear 1134 is attached to the distal end of thedistal power shaft 1130. The distal drive gear 1134 is configured formeshing engagement with the driven firing gear 1614 on the anvil driveshaft 1610 when the anvil assembly 1560 is in the closed position asshown in FIGS. 31 and 32. The anvil drive shaft 1610 is said to be“separate and distinct” from the distal power shaft 1130. That is, atleast in the illustrated arrangement for example, the anvil drive shaft1610 is not coaxially aligned with the distal power shaft 1130 and doesnot form a part of the distal power shaft 1130. In addition, the anvildrive shaft 1610 is movable relative to the distal power shaft 1130, forexample, when the anvil assembly 1560 is moved between open and closedpositions. FIG. 31 illustrates the anvil assembly 1560 in a closedposition and the firing member 1620 in a pre-firing position. As can beseen in that Figure, the distal thread nodule 1626 in the knife nut 1624of the firing member 1620 is engaged with the distal threaded portion1618 such that rotation of the anvil drive shaft 1610 drives (fires) thefiring member 1620 to the end position illustrated in FIG. 32. Furtherdetails regarding the operation of the firing member 1620 are providedbelow.

Opening and Closing Systems

In the illustrated arrangement, the anvil assembly 1560 is closed bydistally advancing a closure tube 1410 that is a portion of the elongateshaft assembly 1400. As can be seen in FIGS. 27 and 31-35, the closuretube 1410 includes an internally threaded closure nut 1412 that isconfigured for threaded engagement with a closure thread segment 1136that is formed on the distal power shaft 1130. FIG. 33 illustrates theanvil assembly 1560 in an open position. As was discussed above, theproximal bearing lug 1612 is rotatably supported in the anvil assembly1560 by a floating bearing housing 1582 that is movably supported in abearing pocket 1574 in the proximal anvil portion 1570. A bearing spring1584 is journaled on the distal power shaft 1130 and is configured toapply a biasing force to the bearing housing 1582 during opening andclosing of the anvil assembly 1560. Such biasing force serves to urgethe anvil assembly 1560 into the open position. In at least onearrangement, the bearing spring 1584 comprises an assembly of plates1586 fabricated from, for example, 17-4, 416 or 304 stainless steel thatare laminated together by a more annealed stainless steel material andwhich have a hole 1588 for receiving the distal power shaft 1130therethrough. See FIG. 36.

As indicated above, the anvil trunnion pins 1572 are received invertically oriented pivot slots 1526 that are formed in the upstandingwalls 1524 of the elongate channel 1520 to afford the anvil assembly1560 with the ability to move vertically relative to the elongatechannel 1520 as well as relative to the surgical staple cartridge 1550supported therein. Such movement of the anvil assembly 1560 relative tothe elongate channel 1520 may serve to accommodate different thicknessesof tissue that is clamped therebetween. To that end, in the illustratedexample, the surgical end effector 1500 also includes an anvil springassembly 1590 for managing the magnitude of the tissue gap between thestaple forming plates 1568 and the upper surface of the surgical staplecartridge 1550. As can be most particularly seen in FIG. 27, the anvilspring assembly 1590 in the illustrated example includes a bearing mount1592 that is mounted between the upstanding walls 1524 of the elongatechannel 1520. As can be seen in FIGS. 27 and 33, the bearing mount 1592has a somewhat U-shaped bearing cavity 1594 therein that is configuredto operably receive therein a shaft bearing 1138 as well as a bearingstop flange 1140 that is formed on or otherwise attached to the distalpower shaft 1130. Such arrangement serves to rotatably support thedistal power shaft 1130 within the proximal end portion or channelmounting portion 1522 of the elongate channel 1520. Two spring tabs 1596extend from the bearing mount 1592 and are oriented to apply a downwardbiasing force to the proximal anvil portion 1570. See FIG. 32. Suchbiasing force serves to bias the proximal anvil portion 1570 downwardsuch that the anvil trunnion pins 1572 are biased downward within theircorresponding vertical pivot slots 1526 and enable the anvil assembly1560 to vertically move to accommodate different thicknesses of tissue.As the anvil assembly 1560 is closed, the target tissue that is capturedbetween the anvil assembly 1560 and the surgical staple cartridge 1550will result in the compression of the cartridge body 1552 and thestaples or fasteners supported therein will be pressed through thetissue into forming contact with the staple forming plates 1568 on theunderside of anvil assembly 1560. Depending upon the arrangement ofstaples of fasteners in the staple cartridge 1550, the staples may beformed in several discreet lines through the staple cartridge body andthe clamped tissue. For example, there may be a total of six lines ofstaples (three lines of staple on each side of a central area throughwhich the firing member 1620 may pass). In at least one arrangement, forexample, the staples in one line may be offset or staggered from thestaples in adjacent lines.

As can be seen in FIG. 33 when the anvil assembly 1560 is in the openposition, the closure thread segment 1136 on the distal power shaft 1130remains in threaded engagement with the closure nut 1412. When in theopen position, the firing member 1620 is located in its proximal-most orstarting position on the proximal threaded portion 1616 of the anvildrive shaft 1610. As can be seen in FIG. 33, when in that proximalstarting position, the channel engagement tabs 1632 on the firing memberare able to clear the channel ledges 1528 formed in the elongate channel1520 to enable the firing member 1620 to pivot with the anvil assembly1560 to the open position. When in that position (which may also bereferred to as a “fully open position”), the driver firing gear 1614 mayremain in contact with the distal drive gear 1134, but it is not inmeshing engagement therewith. Thus, rotation of the distal power shaft1130 will not result in rotation of the anvil drive shaft 1610.

To commence the closing process, the distal power shaft 1130 is rotatedin a first rotary direction. This initial rotation of the distal powershaft 1130 causes the closure tube 1410 to move in the distal directionDD by virtue of the threaded engagement between the closure threadsegment 1136 on the distal power shaft 1130 and the internally threadedclosure nut 1412. As the closure tube 1410 moves distally, a closure tab1414 that is formed on the distal end of the closure tube 1410 contactsthe proximal anvil portion 1570 and moves into camming contact therewithto cause the anvil assembly 1560 to pivot to an initial closed position.Further rotation of the distal power shaft 1130 will result in thedistal movement of the closure tube 1410 until the closure tube reachesa “fully closed” position wherein the internally threaded closure nut1412 has threadably disengaged from the closure thread segment 1136.When in that position, for example, the internally threaded closure nut1412 is distal to the closure thread segment 1136 and further rotationof the distal power shaft 1130 in the first rotary direction will notaffect movement of the closure tube 1410. A closure spring 1416 servesto bias the closure tube 1410 distally to retain the internally threadedclosure nut 1412 out of threaded engagement with the closure threadsegment 1136.

Once the anvil assembly 1560 has been moved to the closed position, thedriven firing gear 1614 on the anvil drive shaft 1610 will now be inmeshing engagement with the distal drive gear 1134 on the distal powershaft 1130. Further rotation of the distal power shaft 1130 in the firstrotary direction will thereby result in the rotation of the anvil driveshaft 1610 and cause the firing member 1620 to move distally on theproximal threaded portion 1616. Continued rotation of the anvil driveshaft 1610 in the first rotary direction will result in the distalmovement of the firing member 1620. FIG. 34 illustrates the position ofthe firing member 1620 just prior to engagement between the distalthread nodule 1626 and the distal threaded portion 1618 of the firingdrive shaft. FIG. 31 illustrates the position of the firing member 1620after the distal thread nodule 1626 has initially threadably engaged thedistal threaded portion 1618 of the anvil drive shaft 1610. When in thatposition, the anvil engaging tabs 1630 on the firing member 1620 haveengaged the corresponding staple forming plates 1568 that are attachedto the anvil frame 1562 and the channel engaging tabs 1632 have engagedthe corresponding ledges 1528 on the elongate channel 1520 to maintain adesired spacing between the anvil assembly 1560 and the elongate channel1520.

Continued rotation of the distal power shaft 1130 in the first rotarydirection causes the anvil drive shaft 1610 to also rotate. Now that thedistal thread nodule 1626 has engaged the distal threaded portion 1618of the anvil drive shaft 1610, the firing member 1620 will move at a“firing speed” that is faster than a “pre-firing speed” that the firingmember 1620 moves when threadably engaged with the proximal threadedportion 1616 of the anvil drive shaft 1610. This speed difference is dueto the differences in the thread leads of the proximal and distalthreaded portions 1616, 1618. As the firing member 1620 moves distallythrough the end effector 1500, the tissue cutting surface 1634 passesbetween the staple forming plates 1568 and cuts through the tissue thathas been clamped between the anvil assembly 1560 and the surgical staplecartridge 1550. Thus, the tissue is first stapled when the anvilassembly 1560 is moved to the fully closed position. The tissue isthereafter cut when the firing member is distally advanced through theend effector 1500. Thus, the staple forming process may “separate anddistinct” from the tissue cutting process.

FIG. 32 illustrates the position of the firing member 1620 at the endfiring position or near the end firing position. Once the firing member1620 has reached the end firing position which may, for example, bedetermined by sensors, encoders, etc.—not shown, the distal power shaft1130 may be rotated in a second rotary direction or “retractiondirection” which also causes the anvil drive shaft 1610 to rotate in theopposite direction. Rotation of the anvil drive shaft 1610 in the secondrotary direction will cause the firing member 1620 to move proximally tothe position shown in FIG. 35. As can be seen in FIG. 35, the closuretube 1410 is fitted with a closure tube reset spring 1418 that extendsdistally from a lug 1413 on the closure nut 1412. The firing member 1620is formed with a proximally extending reset tab 1636 that is configuredto contact and apply a proximal compression force to the closure tubereset spring 1418 when the firing member 1620 returns to the startingposition. Such proximal compression force serves to urge the closuretube 1410 and, more particularly, the internally threaded closure nut1412 against the closure thread segment 1136 on the distal power shaft1130 so that the closure nut threads threadably re-engage the closurethread segment 1136 on the distal power shaft 1130. As the distal powershaft 1130 continues to rotate in the second rotary direction, theinteraction between the closure thread segment 1136 and the closure nut1412 causes the closure tube 1410 to move proximally so that the closuretab 1414 moves out of camming contact with the proximal anvil portion1570 to thereby permit the bearing spring 1584 to urge the anvilassembly 1560 to the open position (FIG. 33). The tissue containedbetween the anvil assembly 1560 and the elongate channel 1520 may alsoserve to urge the anvil assembly 1560 to the open position wherein thetissue may be removed therefrom.

Articulation System

As indicated above, the illustrated example includes an articulationsystem 1700 that facilitates articulation of the surgical end effector1500 about the articulation axis AA that is transverse to the shaft axisSA. In the illustrated example, the surgical end effector 1500 is alsocapable of being selectively rotated about the shaft axis SA distal tothe articulation joint 1702 as represented by arrow 1703 in FIG. 24. Inthe illustrated example, the articulation system 1700 is actuated by thesecond rotary drive system 320 in the handle assembly 20. As wasdiscussed above, the interchangeable surgical tool assembly 1000includes a secondary rotary drive system 1220 that is configured tooperably interface with a second rotary drive system 320 on the handleassembly. In the illustrated arrangement, the secondary rotary drive1220 comprises a portion of the articulation system 1700. In theillustrated example, the articulation system 1700 comprises anarticulation drive shaft 1706 that is rotatably supported on the powershaft support tube 1124. As indicated above, the proximal drive shaft1120 rotatably extends through the power shaft support tube 1124. In theillustrated arrangement, the proximal drive shaft 1120 is coaxiallyaligned on the shaft axis SA. The power shaft support tube 1124 isconfigured such that the articulation drive shaft 1706 is not coaxiallyaligned on the shaft axis SA. Stated another way, the articulation driveshaft 1706 has an articulation drive shaft axis “ADA” that is offsetfrom the shaft axis SA when the articulation drive shaft 1706 is mountedon the power shaft support tube 1124. See FIG. 30. Such arrangementfacilitates the formation of a relatively compact nested geararrangement in the vicinity of the articulation joint 1702 as can beseen in FIG. 38-42. In the illustrated arrangement for example, aproximal articulation driven gear 1708 is mounted to the proximal end ofthe articulation drive shaft 1706. See FIG. 19. The proximalarticulation driven gear 1708 is arranged in meshing engagement with asecondary drive gear 1206 that is mounted to a distal end of thesecondary transfer shaft 1204. Rotation of the secondary transfer shaft1204 and the secondary drive gear 1206 will result in the rotation ofthe proximal articulation driven gear 1708 as well as of thearticulation drive shaft 1706. A distal articulation drive gear 1710 isattached to the distal end of the articulation drive shaft 1706. Thedistal articulation drive gear 1710 is supported in meshing engagementwith a channel articulation gear 1538 that is formed on a channelmounting fixture 1530.

More specifically and with reference to FIGS. 30 and 37, in theillustrated example, the channel mounting fixture 1530 comprises adisc-like body portion 1532 that has a lower shaft attachment tab 1534and an upper shaft attachment tab 1536 formed thereon. The articulationshaft 1704 extends through corresponding holes in the lower and uppershaft attachment tabs 1536, 1534 to be attached to the pivot tabs 1404,1406 in the outer spine tube 1402. Such arrangement serves to permit thechannel mounting fixture 1530 to rotate about the articulation axis AArelative to the outer shaft spine tube 1402. The channel articulationgear 1538 is formed on the lower shaft attachment tab 1534 and isretained in meshing engagement with distal articulation drive gear 1710.Referring now to FIG. 27, in the illustrated example, the channelmounting portion 1522 of the elongate channel 1520 includes anupstanding proximal wall 1523 that has a mounting hub 1525 proximallyprotruding therefrom. A shaft hole 1527 extends through the mounting hub1525 and upstanding proximal wall 1523 that is configured to permit thedistal power shaft 1130 to extend therethrough. In the illustratedexample, the channel mounting fixture 1530 is frictionally mounted onthe mounting hub 1525 to complete the coupling of the end effector 1500to the articulation joint 1702. See FIG. 30.

FIGS. 30, 38 and 39 best illustrate operation of the articulation joint1702. Rotation of the articulation drive shaft 1704 in a first rotarydirection by the second rotary drive system 320 will result in rotationor articulation of the surgical end effector 1500 in an articulationangle 1711 (FIG. 39) relative to the shaft axis SA. In at least oneexample, the articulation angle 1711 may be between 0°-90°, for example.Rotation of the articulation drive shaft 1704 in an opposite rotarydirection will result in the articulation of the surgical end effector1500 in an opposite articulation direction. Once the surgical endeffector 1500 has been articulated to the desired orientation, power tothe second rotary drive system 320 (and ultimately to the secondaryrotary drive system 1200) is discontinued. The friction between thecomponents (i.e., gears) of the secondary rotary drive system 1200, aswell as the components (i.e., gears) of the articulation system 1700,serves to retain the surgical end effector 1500 in the articulatedorientation. In alternative arrangements, however, gears 306 and 326 maybe locked in place. For example, when gear 252 engages these gears, theshifting mechanism that engages gear 252 with gear 306 can disengage thelock. This can be accomplished with a simple cam surface that disengagesthe locking means when the gear 252 moves to engage.

End Effector Rotation

The illustrated interchangeable surgical tool assembly 1000 isconfigured to employ the primary rotary drive system 1100 to selectivelyrotate the surgical end effector 1500 about the shaft axis SA. Inaddition, in the illustrated example, the tertiary axial drive system1300 is configured to selectively lock the surgical end effector 1500 inthe desired rotary orientation. As can be seen in FIGS. 37 and 42, forexample, the elongate shaft assembly 1400 includes an elongate shaftsupport tube 1420 that extends from the tool mounting portion 1010 tojust proximal of the articulation joint 1702. The elongate shaft supporttube 1420 includes an “off-axis” passageway 1422 for rotatablysupporting the articulation drive shaft 1706 therethrough. The elongateshaft support tube 1420 further includes a distal end 1424 that has agear cavity 1426 and a gear axle 1428 formed therein for accommodating alocking gear assembly 1430 therein. See FIG. 37. The locking gearassembly 1430 includes drive gear 1432 that is received within the gearcavity 1426 in the elongate shaft support tube 1420. In addition, thelocking gear assembly 1430 has a smaller driven gear 1434 attachedthereto. As was briefly discussed above, the tertiary axial drive system1300 includes a tertiary actuation shaft 1302 that is also referred toherein as a locking control rod 1302. The locking control rod 1302 has ashaft attachment lug 1306 formed on the proximal end 1304 thereof. Whenthe interchangeable surgical tool assembly 1000 is coupled to the handleassembly 20, the shaft attachment lug 1306 is received in the shaftattachment socket 414 on the distal end 412 of the third drive actuatormember 410. Thus, actuation of the third axial drive 400 will result inthe axial movement of the locking control rod 1302. In the illustratedarrangement, the axially movable locking control rod 1302 has a gearrack 1308 formed in its distal end that is configured for meshingengagement with the driven gear 1434. Axial movement of the lockingcontrol rod 1302 will result in rotation of the locking gear assembly1430 in a first rotary direction about the gear axle 1428 and axialmovement of the locking control rod 1302 in the proximal direction willresult in rotation of the locking gear assembly 1430 in a second rotarydirection.

In the illustrated example, the tertiary drive system 1300 is configuredto operably interface with an end effector rotary locking system 1310.In at least one embodiment, the end effector rotary locking system 1310comprises a rotation locking disc 1320 that includes a disc-like body1322 that has a hollow mounting stem 1324 protruding therefrom. As canbe seen in FIG. 30, the mounting stem 1324 extends through the shafthole 1527 in the mounting hub 1525. The distal end of the mounting stem1324 includes an annular groove 1326 that is configured to receive aninwardly extending fastener flange 1598 that is formed on the bearinghousing 1592 of the anvil spring assembly 1590. The proximal-facingsurface of the disc-like body 1322 of the rotation locking disc 1320 hasa plurality of lock detents 1328 radially arranged thereon. The lockdetents 1328 are arranged to be frictionally engaged by a lock memberthat, in at least one form comprises a lock lug 1332 that is formed on alock gear 1330 that is journaled on the articulation shaft 1704. SeeFIGS. 43 and 44. As can be seen in those Figures, the lock gear 1330 issupported in meshing engagement with drive gear 1432 of the locking gearassembly 1430. Actuation of the tertiary actuation shaft 1302 by thetertiary drive system 1300 will result in rotation of the locking gearassembly 1430. Actuation of the locking gear assembly 1430 will resultin the rotation of the lock gear 1330 about the articulation shaft 1704.When the lock lug 1332 on the lock gear 1330 is in engagement with alock detent 1328, the rotation locking disc 1320, as well as the endeffector 1500, is prevented from rotating about the shaft axis SA. Forexample, the lock lug 1332 frictionally engages the corresponding lockdetent 1328 and serves to urge the rotation locking disc 1320 intofurther frictional engagement with the body portion 1532 of the channelmounting fixture 1530. Such frictional engagement between those twocomponents serves to prevent the locking disc 1320 as well as theelongate channel 1520 from rotating about the shaft axis SA. FIG. 43illustrates the lock lug 1332 in locking engagement with one of the lockdetents 1328 and FIG. 44 illustrates the lock lug 1332 in an unlockedorientation whereby the locking disc 1320 is free to rotate about theshaft axis SA.

In the illustrated embodiment of the interchangeable surgical toolassembly 1000, rotation of the end effector 1500 about the shaft axis SAis controlled by a remote rotation dial 1340 that is rotatably supportedon the nozzle frame 1020. The remote rotation dial 1340 operablyinterfaces with a rheostat mounting assembly 1350 that is mounted withinthe nozzle frame 1020. As can be seen in FIG. 23, for example, theremote rotation dial 1340 includes a plurality of scallops 1341 aroundits perimeter and is accessible on both sides of the nozzle frame 1020.Such arrangement may enable the user to engage and rotate the remoterotation dial 1340 with a finger of the same hand that is gripping thehandle assembly 20 or the remote rotation dial may be engaged with theuser's other hand as well. Referring to FIGS. 18, 20 and 21, therheostat mounting assembly 1350 includes a hollow mounting hub 1352 thathas an annular groove 1354 for receiving a corresponding mountingbulkhead 1028 that is formed in the nozzle frame 1020. In at least onearrangement, the mounting hub 1352 includes an annular retention detent1356 that is configured to retain the remote rotation dial 1340 on thehollow mounting hub 1352 while permitting the remote rotation dial 1340to rotate relative thereto. The rheostat mounting assembly 1350 includesa radially extending flange portion 1358 that supports a collection ofstationary contacts 1360 thereon. See FIG. 18. The flange portion 1358is received within a rheostat cavity 1342 in the remote rotation dial1340. A rotary contact assembly 1344 is mounted within the rheostatcavity 1342 and is configured to interface with the stationary contacts1360 as the remote rotation dial 1340 is rotated on the rheostatmounting assembly 1350. The rheostat mounting assembly is wired to or isotherwise in communication with the tool circuit board 1060.

In at least one arrangement, rotation of the surgical end effector 1500about the shaft axis SA is commenced by rotating the remote rotationdial 1340. In at least one arrangement, the control system or CPU 224 isconfigured to rotate the surgical end effector 1500 in the same rotarydirection as the remote rotation dial 1340 is rotated. Initial rotationof the remote rotation dial 1340 will cause the control system or CPU224 in the handle assembly 20 to activate the third axial drive system400 in the handle assembly 20. In particular, the control system or CPU224 actuates the solenoid 402 which results in the axial movement of thethird actuator member 410. Axial movement of the third actuator member410 results in the axial movement of the tertiary actuation shaft orlocking control rod 1302 which is operably coupled thereto. Axialmovement of the locking control rod 1302 results in the rotation of thelocking gear assembly 1430. Rotation of the locking gear assembly 1430will cause the lock gear 1330 to rotate to the unlocked position (FIG.44). The control system or CPU 224 will then activate the first rotarydrive system 300. The reader will appreciate that because the lock lug1332 has rotated out of engagement with the corresponding lock detent1328 on the rotation locking disc 1320 that the rotation locking disc1320 is now capable of rotating about the shaft axis SA. However,friction between the rotation locking disc 1320 and the mounting hub1525 on the channel mounting portion 1522 may temporarily prevent thesurgical end effector 1500 from rotating.

Actuation of the first rotary drive system 300 will result in theapplication of rotary drive motion to the first drive socket 302 becausethe shifter solenoid 260 has not been actuated and shifter spring 166has biased the shifter gear 250 into meshing engagement with the firstdriven gear 306 on the first drive socket 302. See FIGS. 6 and 7.Rotation of the first drive socket 302 will result in rotation of theprimary transfer shaft 1104 which is in operable engagement with thefirst drive socket 302. Rotation of the primary transfer shaft 1104 willresult in the rotation of the proximal drive gear 1110 that is attachedto the primary transfer shaft 1104. Because the proximal drive gear 1110is in meshing engagement with the power driven gear 1122 that isattached to the proximal drive shaft 1120, the proximal drive shaft 1120is also rotated. See FIG. 19.

Referring now to FIG. 30, rotation of the proximal drive shaft 1120 willultimately result in the rotation of the distal driven gear 1132 that isattached to the distal power shaft 1130. Rotation of the distal drivengear 1132 will result in rotation of the distal power shaft 1130. Thefriction between the distal power shaft 1130 and the rotation lockingdisc 1320, as well as the friction between the bearing housing 1592 andthe distal power shaft 1130 and the rotation locking disc 1320, as wellas the friction between the closure nut 1412 of the closure tube 1410and the closure thread segment 1136 on the distal power shaft 1130 intotal (“second amount of friction”) is greater than the friction betweenthe mounting hub portion 1525 of the elongate channel 1520 and thechannel mounting fixture 1530, as well as the friction between therotation locking disc 1320 and the channel mounting fixture 1530 intotal (“first amount of friction”) so as to permit the elongate channel1520 and closure tube 1410 to rotate with the distal power shaft 1130relative to the channel mounting fixture 1530 about the shaft axis SA.In one arrangement, for example, the rotary position of the remoterotation dial 1340 will, through the control system or CPU 224,determine the rotary position of the distal power shaft 1130 andultimately the surgical end effector 1500. Once the user has positionedthe surgical end effector 1500 in the desired rotary position about theshaft axis SA and has discontinued rotation of the remote rotation dial1340, the control system or CPU 224 will discontinue power to the firstrotary drive system 300 as well as to the third axial drive system 400.In at least one embodiment, the solenoid 402 is “spring loaded” suchthat upon deactivation, the spring component thereof will bias the thirddrive actuator member 410 distally which will result in the proximalmovement of the locking control rod 1302. Such axial movement of thelocking control rod 1302 will result in the rotation of the lock gear1330 to thereby bring the lock lug 1332 into retaining engagement withthe corresponding lock detent 1328 on the rotation locking disc 1320 andthereby lock the surgical end effector 1500 into that rotaryorientation. Thus, should power be lost to the handle assembly 20 and,more particularly to the third drive system 400, the solenoid springwill cause the end effector rotary locking system 1310 to move to thelocked orientation to thereby prevent rotation of the surgical endeffector 1500 relative to the elongate shaft assembly 1400. As can beappreciated from the foregoing discussion, when the interchangeablesurgical tool assembly 1000 is operably coupled to the handle assembly20, the third axial drive system 400 is employed to unlock the endeffector locking system 1310 and the first rotary drive system 300 isemployed to rotate the surgical end effector 1500 relative to theelongate shaft assembly 1400. The reader will appreciate that suchrotation of the surgical end effector 1500 is completely distal to thearticulation joint 1702. Thus, the outer spine tube 1402, as well as thearticulation joint 1702, remain stationary during the rotation process.

One general method of operating and controlling the surgical instrument10 will now be described. FIG. 1 illustrates the surgical instrument 10after the interchangeable surgical tool assembly 1000 has been operablyattached to the handle assembly 20. As indicated above, coupling thetool attachment module portion 1010 of the interchangeable surgical toolassembly 1000 to the tool attachment portion 500 of the handle assembly20 causes the tool circuit board 1060 to be coupled to or otherwisecommunicate with the handle circuit board 220 that comprises the controlsystem or CPU 224. Once connected or in communication with the controlsystem or CPU 224, the tool circuit board 1060 may provide specificsoftware to the control system or CPU 224 that is unique to thatparticular interchangeable surgical tool assembly. The clinician mayalso position the grip portion 100 of the handle assembly 20 in thedesired position relative to the primary housing portion 30 that may bebest suited for the type of interchangeable surgical tool assembly beingused.

As can be seen in FIG. 3, the illustrated handle assembly 20 includesright and left control button assemblies 270R, 270L that interface withthe control system or CPU 224. In one exemplary arrangement, eachcontrol button assembly 270R, 270L includes a first button 272, a secondbutton 274 and a third button 276 that each interface with the controlsystem or CPU 224. It will be understood that in at least oneembodiment, the control button 272 on the right control button assembly270R may perform the same control function as the control button 272 onthe left control button assembly 270L. Similarly, the control button 274on the right control button assembly 270R may perform the same controlfunction as the control button 274 on the left control button assembly270L. Likewise, the control button 276 on the right control buttonassembly 270R may perform the same control function as the controlbutton 276 on the left control button assembly 270L. Such arrangementsenable the clinician to control the surgical instrument from both sidesof the handle assembly 20. In at least one arrangement, the controlbuttons 272, 274, 276 comprise “Hall Effect” sensors or linear sensorsso actuation of the buttons can indicate the intensity of the user'srequest as well as the speed desired, for example.

In one arrangement, the first and second control buttons 272, 274 may beused to control operation of the articulation system 1700. For example,the control button 272 may be used to initiate articulation of thesurgical end effector 1500 about the articulation axis AA to the right(arrow “R” in FIG. 1). Upon actuation of the first control button 272,the control system or CPU 224 activates the shifter solenoid 260 of therotary drive selector system 240 to move the shifter gear 250 intomeshing engagement with the second driven gear 326 on the second drivesocket 322. Thereafter, the control system 224 or CPU actuates the motor200 to apply rotary motion to the second rotary drive system 320 in therotary direction necessary to cause the articulation system 1700 toarticulate the surgical end effector to the right (arrow R). In onearrangement, the amount of depression or actuation force applied to thecontrol button, may dictate the speed at which the motor rotates. Inaddition, or in the alterative, the clinician may also depress therocker switch 206 to affect the motor rotation speed. Once the surgicalend effector 1500 has been articulated to the desired position, the userdiscontinues actuation of the first control button 270 (and the rockerswitch 206). Once the control button 270 has been deactivated, thecontrol system or CPU 224 deactivates the shifter solenoid 260. Thespring component of the shifter solenoid 260 moves the shifter gear 250into meshing engagement with the first driven gear 306 on the firstdrive socket 302. Thus, further actuation of the motor 200 will resultin actuation of the first rotary drive 300. Actuation of the secondcontrol button 274 will operate in the same manner, but will result inrotation of the motor 200 so as to cause the articulation system 1700 toarticulate the surgical end effector 1500 to the left (arrow L in FIG.1).

As was discussed above, the surgical end effector 1500 may also berotated about the shaft axis relative to the articulation joint 1702. Tocommence rotation of the surgical end effector 1500, the clinicianrotates the remote rotational dial 1340 in the rotary direction in whichhe or she intends the surgical end effector 1500 to rotate. Rotation ofthe remote rotation dial 1340 causes the control system or CPU 224 toactuate the third axial drive system 400. In particular, the solenoid402 is actuated to axially move the third drive actuator member 410 andthe locking control rod 1302 in the proximal direction. As the lockingcontrol rod 1302 moves proximally, the gear rack 1308 causes the lockinggear assembly 1430 to rotate the lock gear 1330 so as to disengage thelock lug 1332 from the corresponding lock detent 1328 in the rotationlocking disc 1320. See FIGS. 41 and 42. The control system or CPUretains the solenoid 402 in that actuated orientation and then activatesthe motor 200 to apply rotary motion to the first rotary drive system300 in the direction necessary to rotate the surgical end effector 1500in the desired rotary direction. Actuation of the first rotary drivesystem 300 will result in rotation of the distal drive shaft 1130 whichwill result in rotation of the surgical end effector 1500 about theshaft axis SA. Once the surgical end effector 1500 has been rotated tothe desired position, rotation of the remote rotation dial 1340 by theclinician is discontinued. Thereafter, the control system or CPU 224will deactivate the motor 200 as well as the solenoid 402. The springcomponent of the solenoid 402 will then bias the third drive actuatormember 410 and the locking control rod 1302 in the distal position tothereby cause the lock gear 1330 to rotate in an opposite direction soas to cause the lock lug 1332 to engage the corresponding lock detent1328 in the rotation locking disc 1320. The surgical end effector 1500is locked in that rotary position.

In at least one arrangement, the third buttons 276 may comprise a “homestate” button that communicates with the control system or CPU 224 toreturn the surgical end effector 1500 to a home state wherein thesurgical end effector is unarticulated and also rotated back to an ininitial rotary orientation. For example, when the third button 276 isactuated, the CPU may unlock the end effector rotary locking system 1310by actuating the solenoid 402 to cause the lock lug 1332 to disengagefrom the rotation locking disc 1320 and then actuate the first rotarydrive system 300 to cause the surgical end effector to rotate back to astarting rotary position. Thereafter, the solenoid 402 is de-actuated tocause the lock lug 1332 to re-engage the rotation locking disc to lockthe surgical end effector 1500 in that rotary orientation. The controlsystem or CPU 224 may then actuate the shifter solenoid 260 to bring theshifter gear 250 into meshing engagement with the second driven gear 326on the second drive socket 322. After the second rotary drive system 320is ready for actuation, the control system or CPU 224 may then actuatethe motor 200 to return the surgical end effector 1500 to theunarticulated position.

Once the surgical end effector 1500 has been rotated and/or articulatedinto a desired configuration, discontinuing actuation of thearticulation system 1700 as well discontinuing rotation of the remoterotation dial 1340 will result in the motor 200 being operably engagedwith the first rotary drive system 300 in the manner discussed herein.The clinician may then manipulate the surgical end effector 1500 so asto position the target tissue between the anvil assembly 1560 and thesurgical staple cartridge 1550. The clinician may commence the closingand firing processes by actuating the rocker switch 206. Actuation ofthe rocker switch 206 will cause the control system or CPU 224 toactuate the motor 200 to cause the motor to apply a rotary controlmotion in a first rotary direction to the first rotary drive system 300.Rotation of the first rotary drive system 300 will cause the distalpower shaft 1130 to rotate and commence the closing process in themanner described above. Once the anvil assembly 1560 is fully closed,the control system or CPU 224 may stop the motor 200 and provide theclinician with an indication (sound, vibration, notice on a displayscreen, etc.) that the anvil is fully closed. This may happen regardlessof whether the rocker switch 206 remains actuated or not. Then, when theclinician desires for the firing member to cut the target tissue whichwas stapled during the closing process, the clinician may thenre-actuate the rocker switch 206 to start the motor and cause the firingmember to be distally driven through the end effector in theabove-described manner. The rocker switch 206 may be configured suchthat the speed in which the motor rotates is proportional to thedistance that the rocker switch is depressed or otherwise actuated. Inother arrangements, the control system or CPU 224 may not stop the motorbetween the closure and firing sequences. Various forms of sensorsand/or encoders may be employed to monitor the position of the firingmember during the firing process. Once the firing member has reach theending position, the rotary direction of the motor is reversed by thecontrol system or CPU 224 until the firing member as returned to thestarting position wherein the anvil assembly 1560 is biased to the openposition in the above described manner.

FIGS. 40A and 40B illustrate one example arrangement for supplyingelectrical signals from the circuit board 1060 in the tool attachmentmodule portion 1010 to the end effector attached thereto while enablingthe end effector to be selectively articulated and rotated in thevarious manners described herein. As can be seen in those Figures,conductors (wires) 1401A, 1401B extend along the exterior of the outerspine tube 1402 of the elongate shaft assembly. The conductors 1401A,1401B extend from the tool attachment module 1010 along the spine tube1402 and enter a hole 1531 in the channel mounting fixture 1530. Toaccommodate articulation of the end effector about the articulationjoint 1702, a loop 1403 may be provided in the conductors 1401A, 1401Bto provide a sufficient amount of slack therein. Conductor 1401A extendsinto the channel mounting fixture 1530 and has a proximally-facingcontact 1405A attached thereto. Similarly, conductor 1401B extends intothe channel mounting fixture 1530 and has a proximally-facing contact1405B attached thereto. These contacts 1405A, 1405B correspond toconductive tracks 1325A, 1325B, respectively that are mounted on thedistal surface 1323 of the disc-like body 1322 of the rotation lockingdisc 1320. When assembled together, contact 1405A is in rotationalelectrical contact with track 1325A and contact 1405B is in rotationalelectrical contact with track 1325B. Such arrangement permits relativerotation of the channel mounting fixture 1530 and the rotation lockingdisc 1320 while facilitating electrical contact between the conductors1401A, 1401B and the tracks 1325A, 1325B. End effector wires 1327A,1327B are attached to the tracks 1325A, 1325B, respectively and extendthrough the hollow mounting stem 1324 of the rotation locking disc 1320.The end effector wires 1327A, 1327B may then be attached to sensors,lights, etc. in the end effector. Such arrangement serves to supplyelectrical power to the end effector from the tool attachment module1010 while facilitating articulation and rotation of the end effector.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Paten Application Publication No. 2012/0298719,for example, discloses several examples of a robotic surgical instrumentsystem in greater detail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

-   -   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC        DEVICE, which issued on Apr. 4, 1995;    -   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT        HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which        issued on Feb. 21, 2006;    -   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING        AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which        issued on Sep. 9, 2008;    -   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL        INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS,        which issued on Dec. 16, 2008;    -   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN        ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;    -   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,        which issued on Jul. 13, 2010;    -   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE        IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;    -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL        INSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No.        7,845,537;    -   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL        CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed        Feb. 14, 2008;    -   U.S. patent application Ser. No. 12/031,873, entitled END        EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed        Feb. 15, 2008, now U.S. Pat. No. 7,980,443;    -   U.S. patent application Ser. No. 12/235,782, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No.        8,210,411;    -   U.S. patent application Ser. No. 12/249,117, entitled POWERED        SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY        RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;    -   U.S. patent application Ser. No. 12/647,100, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR        DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009; now U.S. Pat.        No. 8,220,688;    -   U.S. patent application Ser. No. 12/893,461, entitled STAPLE        CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;    -   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL        STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.        8,561,870;    -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL        STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT        ARRANGEMENTS, now U.S. Pat. No. 9,072,535;    -   U.S. patent application Ser. No. 13/524,049, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE,        filed on Jun. 15, 2012; now U.S. Pat. No. 9,101,358;    -   U.S. patent application Ser. No. 13/800,025, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263551;    -   U.S. patent application Ser. No. 13/800,067, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263552;    -   U.S. Paten Application Publication No. 2007/0175955, entitled        SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER        LOCKING MECHANISM, filed Jan. 31, 2006; and    -   U.S. Paten Application Publication No. 2010/0264194, entitled        SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,        filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby        incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Also, where materials are disclosed for certaincomponents, other materials may be used. Furthermore, according tovarious embodiments, a single component may be replaced by multiplecomponents, and multiple components may be replaced by a singlecomponent, to perform a given function or functions. The foregoingdescription and following claims are intended to cover all suchmodification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical instrument, comprising: a housingassembly; a motor assembly operably supported in said housing assembly;at least one rotary drive system comprising: a system drive shaftrotatably supported by said housing assembly; a driven bevel gearaxially movable on said system drive shaft between a first positionwherein said driven bevel gear is in meshing engagement with a driverbevel gear of said motor assembly and a second position wherein saiddriven bevel gear is out of meshing engagement with said driver bevelgear; and a drive system biasing member for biasing said driven bevelgear into said second position; and a bailout system comprising: abailout drive train supported by said housing assembly and configuredfor selective operable engagement and disengagement with said at leastone rotary drive system; and a bailout handle assembly selectivelymovable between a stored position within said housing assembly and anactuation position such that, when said bailout handle assembly is insaid stored position, said at least one rotary drive system is retainedin operable engagement with said motor assembly and when said bailouthandle assembly is in said actuation position, said bailout drive trainis in operable engagement with said at least one rotary drive system,and wherein said housing assembly further comprises a bailout accesspanel that is maneuverable between a closed position wherein saidbailout handle assembly is completely enclosed within said housingassembly in said stored position and an open position wherein saidbailout handle assembly is actuatable such that a portion of saidbailout access panel is configured to bias said driven bevel gear intosaid first position when said bailout access panel is in said closedposition.
 2. The surgical instrument of claim 1, wherein when saidbailout access panel is in said closed position, said bailout accesspanel positively retains said at least one rotary drive system inoperable engagement with said motor assembly and prevents said bailoutdrive train from operable engagement with said motor assembly.
 3. Thesurgical instrument of claim 1, wherein said bailout access panel isremovably attachable to said housing assembly.
 4. The surgicalinstrument of claim 1, wherein said bailout drive train comprises: abailout drive shaft operably interfacing with said bailout handleassembly such that manual actuation of said bailout handle assemblyapplies rotary motion to said bailout drive shaft; a bailout driven gearon said system drive shaft; a bailout drive gear axially movable on saidbailout drive shaft between an unactuated position wherein said bailoutdrive gear is not in meshing engagement with said bailout driven gearand an actuated position wherein said bailout drive gear is in meshingengagement with said bailout driven gear; and a bailout biasing memberconfigured to bias said bailout drive gear into meshing engagement withsaid bailout driven gear when said bailout access panel is in said openposition.
 5. The surgical instrument of claim 4, wherein said bailoutaccess panel is configured to bias said bailout drive gear out ofmeshing engagement with said bailout driven gear when said bailoutaccess panel is in said open position.
 6. The surgical instrument ofclaim 1, further comprising a bailout handle biasing member for biasingsaid bailout handle assembly to said actuation position when saidbailout access panel is in said open position.
 7. The surgicalinstrument of claim 6, wherein said bailout handle assembly isconfigured to apply rotary motions to a bailout drive shaft uponapplication of manually-generated ratcheting motions thereto.
 8. Asurgical instrument, comprising: a housing assembly; a motor assemblyoperably supported within a portion of said housing assembly; at leastone rotary drive system supported by said housing assembly andconfigured for selective operable engagement and disengagement with saidmotor assembly; an access panel interfacing with said housing assemblyand being maneuverable between an open position and a closed position,said access panel operably interfacing with said at least one rotarydrive system to positively retain said at least one rotary drive systemin operable engagement with said motor assembly when said access panelis in said closed position; and means for disengaging said at least onerotary drive system from said motor assembly and manually applying arotary motion to said at least one rotary drive system upon manipulationthereof when said access panel has been maneuvered to said openposition.
 9. A surgical instrument, comprising: a handle assemblyconfigured for operable attachment to a surgical tool assembly, aportion of said handle assembly being maneuverable between an openposition and a closed position; a motor assembly operably supported bysaid handle assembly; at least one rotary drive system operablysupported by said handle assembly and being configured for selectiveoperable engagement and disengagement with said motor assembly; and abailout system, comprising: a bailout drive train supported by saidhandle assembly and configured for selective operable engagement anddisengagement with said at least one rotary drive system; a bailoutactuator assembly selectively movable between a stored position withinsaid handle assembly and an actuation position such that, when saidbailout actuator assembly is in said stored position, said at least onerotary drive system is retained in operable engagement with said motorassembly and when said bailout actuator assembly is in said actuationposition, said bailout drive train is in operable engagement with saidat least one rotary drive system; and an actuator biaser configured tobias said bailout actuator assembly from said stored position to saidactuation position when said portion of said handle assembly ismaneuvered into said open position.
 10. The surgical instrument of claim9, wherein said portion of said handle assembly comprises a bailoutaccess panel that is maneuverable between said closed position and saidopen position, wherein said bailout actuator assembly is completelyenclosed within said handle assembly in said stored position when saidbailout access panel is in said closed position, wherein said bailoutactuator assembly is in said actuation position when said bailout accesspanel is in said open position, and wherein said bailout actuatorassembly is manually actuatable when said bailout actuator assembly isin said actuation position.
 11. The surgical instrument of claim 10,wherein said bailout access panel is removably attachable to said handleassembly.
 12. The surgical instrument of claim 10, wherein when saidbailout access panel is in said closed position, said bailout accesspanel positively retains said at least one rotary drive system inoperable engagement with said motor assembly and prevents said bailoutdrive train from operably engaging said motor assembly.
 13. The surgicalinstrument of claim 10, wherein said at least one rotary drive systemcomprises: a system drive shaft rotatably supported by said handleassembly; a driven bevel gear axially movable on said system drive shaftbetween a first position wherein said driven bevel gear is in meshingengagement with a driver bevel gear of said motor assembly and a secondposition wherein said driven bevel gear is out of meshing engagementwith said driver bevel gear; and a drive system biasing member forbiasing said driven bevel gear into said second position and wherein aportion of said bailout access panel is configured to bias said drivenbevel gear into said first position when said bailout access panel is insaid closed position.
 14. The surgical instrument of claim 13, whereinsaid bailout drive train comprises: a bailout drive shaft operablyinterfacing with said bailout actuator assembly such that manualactuation of said bailout actuator assembly will apply rotary motion tosaid bailout drive shaft; a bailout driven gear on said system driveshaft; a bailout drive gear axially movable on said bailout drive shaftbetween an unactuated position wherein said bailout drive gear is not inmeshing engagement with said bailout driven gear and an actuatedposition wherein said bailout drive gear is in meshing engagement withsaid bailout driven gear; and a bailout biasing member configured tobias said bailout drive gear into meshing engagement with said bailoutdriven gear when said bailout access panel is in said open position. 15.The surgical instrument of claim 14, wherein said bailout access panelis configured to bias said bailout drive gear out of meshing engagementwith said bailout driven gear when said bailout access panel is in saidopen position.
 16. The surgical instrument of claim 10, wherein saidbailout actuator assembly is configured to apply rotary motions to abailout drive shaft upon application of manually-generated ratchetingmotions thereto.
 17. The surgical instrument of claim 10, wherein saidat least one rotary drive system comprises: a system drive shaftrotatably supported by said handle assembly; a driven bevel gear axiallymovable on said system drive shaft between a first position wherein saiddriven bevel gear is in meshing engagement with a driver bevel gear ofsaid motor assembly and a second position wherein said driven bevel gearis out of meshing engagement with said driver bevel gear; a drive systembiasing member for biasing said driven bevel gear into said secondposition, wherein a portion of said bailout access panel is configuredto bias said driven bevel gear into said first position when saidbailout access panel is in said closed position; a first rotary drivesystem configured to apply first rotary drive motions to the surgicaltool assembly coupled to said handle assembly; a second rotary drivesystem configured to apply second rotary drive motions to the surgicaltool assembly coupled to said handle assembly; and a rotary driveselector system operably interfacing with said system drive shaft forselectively operably engaging said first and second rotary drive systemsto said system drive shaft.
 18. The surgical instrument of claim 10,wherein said bailout actuator assembly comprises a bailout leverpivotally supported by said handle assembly for pivotal travel betweensaid stored position and said actuation position.